Page 1
SVM138-A
June, 1998
Safety Depends on You
Lincoln arc welding equipment
is designed and built with safety
in mind. However, your overall
safety can be increased by
proper installation. . . and
thoughtful operation on your
part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READING THIS MANUAL AND THE
SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.
SERVICE MANUAL
For use with machines having Code Numbers: 9100 and Above
LN-9 GMA Wire Feeder
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors
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Page 2
FOR ENGINE
powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b.Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
____________________________________________________
1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop
the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. Do
not spill fuel when filling tank. If fuel is spilled,
wipe it up and do not start engine until fumes
have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts
when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
___________________________________________________
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
i
SAFETY
i
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society , P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
WARNING
Mar ‘95
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1.
Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
The Above For Diesel Engines
The Above For Gasoline Engines
LN-9 GMA Wire Feeder
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SAFETY
ii ii
ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
ELECTRIC SHOCK can kill.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f.
Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
FUMES AND GASES
can be dangerous.
5.a.Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
5.b.
Do not weld in locations near chlorinated hydrocarbon
vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
to
form phosgene, a highly toxic gas, and other irritating
products.
5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.e. Also see item 1.b.
LN-9 GMA Wire Feeder
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SAFETY
iii iii
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
•Away from areas where they may be struck or subjected to
physical damage.
•A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
WELDING SPARKS can
cause fire or explosion.
6.a.
Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
the welding sparks from starting a fire.
Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
though
they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Preparation
for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f.
Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
This can create fire hazards or overheat lifting chains or
cables until they fail.
6.h. Also see item 1.c.
LN-9 GMA Wire Feeder
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SAFETY
iv iv
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suivantes:
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la
peau nue ou les vétements mouillés. Porter des gants
secs et sans trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement
dans les positions assis ou couché pour lesquelles une
grande partie du corps peut être en contact avec la
masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
d. Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous ten-
sion des porte-électrodes connectés à deux machines à
souder parce que la tension entre les deux pinces peut
être le total de la tension à vide des deux machines.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enroule le câble-électrode autour de n’importe quelle partie du
corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du
rayonnement de l’arc et des projections quand on soude
ou quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnementde
l’arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laiter en fusion sont émises de l’arc de
soudage. Se protéger avec es vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir ttout risque d’incendie dû étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé
de la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de la faire. Si on place
la masse sur la charpente de la construction ou d’autres
endroits éloignés de la zone de travail, on augmente le
risque de voir passer le courant de soudage par les chaines
de levage, câbles de grue, ou atres circuits. Cela peut
provoquer des risques d’incendie ou d’echauffement des
chaines et des câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumées toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opéerations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les
vapeurs du solvant pour produire du phosgéne (gas fortement roxique) ou autres produits irritants.
PRÉCAUTIONS DE SÛRETÉ POUR LES
MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code
de l’électricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à
une bonne mise à la terre.
2. Autant que possible, l’installation et l’entretien du poste
seront effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la
debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispostifis de sûreté à leur
place.
LN-9 GMA Wire Feeder
Page 6
MASTER TABLE OF CONTENTS
v v
Page
Safety.................................................................................................................................................i-iv
Installation.............................................................................................................................Section A
Technical Specifications..............................................................................................................A-2
Installing the LN-9GMA 2-Roll and 4-Roll Models ......................................................................A-3
Installing the LN-9F GMA 2-Roll and 4-Roll Models...................................................................A-3
Electrical Connections - LN-9 GMA and LN-9F GMA.................................................................A-4
Machine Grounding ...................................................................................................................A-12
Work Cable Connection............................................................................................................A-12
Connecting the Gun Cable to the Wire Feeder ........................................................................A-13
Hooking Up GMA Shielding Gas...............................................................................................A-14
Operation...............................................................................................................................Section B
Operating Instructions.................................................................................................................B-2
Safety Precautions......................................................................................................................B-2
General Description ....................................................................................................................B-3
Recommended Processes and Equipment.................................................................................B-3
Controls and Settings..................................................................................................................B-5
Drive Roll Installation ................................................................................................................B-10
Wire Loading.............................................................................................................................B-14
Idle Roll Pressure Setting .........................................................................................................B-18
Making a Test Weld and Adjusting Response and Starting......................................................B-19
Procedure at End of Coil...........................................................................................................B-21
Security of Weld Procedure Settings........................................................................................B-21
Accessories ..........................................................................................................................Section C
Auxiliary Equipment Contacts.....................................................................................................C-2
Optional Equipment and Accessories .........................................................................................C-2
Maintenance..........................................................................................................................Section D
Routine Maintenance..................................................................................................................D-2
Periodic Maintenance .................................................................................................................D-2
Gun and Cable Maintenance......................................................................................................D-3
Theory of Operation .............................................................................................................Section E
LN-9 GMA Wire Feeder
RETURN TO MAIN INDEX
Page 7
MASTER TABLE OF CONTENTS
(cont’d)
vi vi
Troubleshooting....................................................................................................................Section F
How to Use Troubleshooting Guide............................................................................................F-2
PC Board Troubleshooting Procedures.......................................................................................F-3
Troubleshooting Guide................................................................................................................F-4
Electrical Diagrams..............................................................................................................Section G
Parts...................................................................................................................................P289 Series
LN-9 GMA Wire Feeder
RETURN TO MAIN INDEX
Page 8
NOTES
vii vii
LN-9 GMA Wire Feeder
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Page 9
TABLE OF CONTENTS
- INSTALLATION SECTION -
Section A-1
Section A-1
Installation
Technical Specifications..............................................................................................................A-2
Installing the LN-9GMA 2-Roll and 4-Roll Models ......................................................................A-3
Attaching the Wire Reel stand ..............................................................................................A-3
Mounting the Unit .................................................................................................................A-3
Installing the LN-9F GMA 2-Roll and 4-Roll Models...................................................................A-3
Mounting the Wire Feed Unit................................................................................................A-3
Mounting the Control Box.....................................................................................................A-3
Connecting the Wire Feed Unit to the Control Box..............................................................A-3
Routing the Electrode...........................................................................................................A-4
Electrical Connections - LN-9 GMA and LN-9F GMA.................................................................A-4
Power Input Cable Assembly ..............................................................................................A-4
Connecting the Power Input Cable Assembly to the LN-9 GMAWire Feed Unit ................A-4
Connecting the Power Input Cable Assembly to the LN-9F GMAWire Feed Unit .............A-5
Connecting the Power Input Cable Assembly to Power Sources........................................A-5
Machine Grounding ...................................................................................................................A-12
Work Cable Connection............................................................................................................A-12
Direct Work Lead Connection.............................................................................................A-12
Connecting the Gun Cable to the Wire Feeder ........................................................................A-13
For GMA Gun Cables .........................................................................................................A-13
Hooking Up GMA Shielding Gas...............................................................................................A-14
LN-9 GMA Wire Feeder
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Page 10
INSTALLATION
A-2 A-2
LN-9 GMA Wire Feeder
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TECHNICAL SPECIFICATIONS
INPUT POWER
Supplied by power source: 115 VAC, 50/60 Hz., 350 VA
WIRE FEED SPEED
80 to 980 inches per minute (2.03 to 24.9 meters per minute)
VOLTAGE CONTROL RANGE
12.0 TO 60.0 VDC
TEMPERATURE RANGE
OPERATION: - 20oC to +40oC (- 4oF to +104oF) Recommended
- 40oC to +40oC (- 40oF to +104oF) Maximum Rated
STORAGE: - 40oC to +85oC (- 40oF to +185oF)
WIRE DIAMETERS
0.023 through 1/16 Solid Electrode
0.045 through 5/64 Cored Electrode
PHYSICAL DIMENSIONS
LENGTH WIDTH HEIGHT TOTAL WEIGHT LESS
ELECTRODE
LN-9 GMA (2 ROLL) 12.15 in. 11.56 in. 12.19 in. 29.3 lbs
(308.4 mm) (293.4 mm) (309.4 mm) (13.3 kg)
LN-9 GMA (4 ROLL) 12.15 in. 11.56 in. 12.19 in. 27.5 lbs
(308.4 mm) (293.4 mm) (309.4 mm) (12.4 kg)
LN-9F GMA Control Box 10.4 in. 6.17 in. 11.26 in. 16.3 lbs
(264 mm) (156.6 mm) (293.4 mm) (7.4 kg)
LN-9F GMA Wire Drive (2 ROLL) 8.06 in. 7.5 in. 12.78 in. 15.6 lbs
(204.6 mm) (190.4 mm) (324.4 mm) (7.1 kg)
LN-9F GMA Wire Drive (4 ROLL) 8.06 in. 7.5 in. 12.78 in. 20.5 lbs
(204.6 mm) (190.4 mm) (324.4 mm) (9.2 kg)
Page 11
INSTALLING THE LN-9 GMA
2-ROLL AND 4-ROLL MODELS
ATTACHING THE WIRE REEL STAND
Both the 2-Roll and 4-Roll LN-9 GMAare shipped without the wire reel stand attached. The screws and washers for mounting the wire reel stand are included with
the LN-9 GMA (fastened in their respective mounting
holes). To attach the stand:
1. Remove the three 3/8" hex screws from the back of
the wire feed unit.
2. Place the wire reel stand mounting bracket in position against the back of the wire feed unit.
3. Replace and tighten the screws. The long screw
and plain washer go into the top hole. For 4-Roll
feeders, one plain washer is used for mounting 60#
wire stands and 2 plain washers for mounting 30#
stands.
MOUNTING THE UNIT
LN-9 GMAwire feeders can be mounted directly on top
of their power source as long as it is secure and level.
When portability is required, the LN-9 GMA can be
mounted on a K163 undercarriage See the
Accessories
section for details.
AK1557-1 swivel platform is available for mounting the
LN-9 GMA to the power source. See the
Accessories
section for details.
INSTALLING THE LN-9F GMA
2-ROLL AND 4-ROLL MODELS
MOUNTING THE WIRE FEED UNIT
Mount the wire feed unit by means of the insulated
mounting bracket attached to the bottom of the gearbox. Refer to the LN-9F GMA Dimension Print in the
Diagrams
section of this manual for the size and location of the mounting holes. The gearbox assembly is
electrically "hot" when the gun trigger is pressed.
Therefore, make certain the gearbox does not come in
contact with the structure on which the unit is mounted.
The wire feed unit should be mounted so that the drive
rolls are in a vertical plane so dirt will not collect in the
drive roll area. Position the mechanism so it will point
down at about a 45oangle so the wire feed gun cable
will not be bent sharply as it comes from the unit.
MOUNTING THE CONTROL BOX
The same control box is used for both the 2-Roll and 4Roll wire feed unit. It contains two keyhole slots and
one slot for mounting. Refer to the LN-9F GMA
Dimension Print in the
Diagrams
section of this manual for the size and location of these slots. Mount the
box at some convenient location close to the wire feed
unit. This will enable the 16-foot control cable assembly supplied with both the LN-9F GMA2-Roll and 4-Roll
to reach between the control box and the wire feed
unit.
1. Drill the required holes in the mounting surface.
Partially install 1/4-20 screws.
2. Open the control box door by removing the two door
screws.
3. Mount the box.
4. Tighten the screws.
5. Close the control box door and replace the door
screws.
CONNECTING THE WIRE FEED UNIT TO
THE CONTROL BOX
Both the LN-9F GMA 2-Roll and 4-Roll include the
same 16 ft. control and electrode cable assembly.
Connect the wire feed unit to the control box as follows:
1. Make certain the cables are protected from any
sharp corners that may damage their jackets.
Mount the cable assembly along the boom so the
end with the female amphenol connector pins is at
the wire feed unit.
2. Connect the cable connector to the receptacle on
the back of the wire feed unit connection box.
3. At the same end, connect the electrode lead to the
connection stud of the copper strap along the side
of the wire feed unit.
4. At the control box end, connect the amphenol con-
nector of the control cable to the mating MS-type
receptacle on the bottom of the control box. (See
Figure A.3,
later in this section, for the location of
this connection.)
INSTALLATION
A-3 A-3
LN-9 GMA Wire Feeder
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Page 12
ROUTING THE ELECTRODE
The electrode supply may be either from reels, ReadiReels, spools, or bulk packaged drums or reels.
Observe the following precautions:
• The electrode must be routed to the wire feed unit so
that the bends in the wire are at a minimum. The
force required to pull the wire from the reel into the
wire feed unit must be kept at a minimum.
• The electrode is "hot" when the gun trigger is
pressed and must be insulated from the boom and
structure.
• If more than one wire feed unit share the same
boom, their wire and reels must be insulated from
each other and insulated from their mounting structure.
See the
Accessories
section for information about
mounting a K299 wire reel assembly.
ELECTRICAL CONNECTIONS LN-9 GMA AND LN-9F GMA
POWER INPUT CABLE ASSEMBLY
A special cable assembly is required to connect all LN9 GMA models to the power source. The assembly
includes control cable and electrode cable. Various
sizes are available, based on length and maximum
welding current. The following power source cable
assemblies are available:
K196 for Terminal Strip control connection and output
terminal.
K595 for 14-Pin receptacle and output terminal.
K596 for 14-Pin receptacle and Twist-Mate" connec-
tion.
NOTE: Use of an LN-9 GMA with a Pulse Power 500,
Invertec V300 or a DC650 PRO requires a K442-1
Pulse Power Filter Kit.
CONNECTING THE POWER INPUT
CABLE ASSEMBLY TO THE LN-9 GMA
WIRE FEED UNIT
The K196, K595, or K596 cable assembly consists of
an electrode cable and multiconductor control cable.
The control cable has a polarized plug on the wire
feeder end. To install:
1. See Figure A.1. Connect the polarized plug of the
control cable to the mating connector on the back
of the wire feeder.
2. See
Figure A.2.
Remove the screws holding the
cable strain relief clamp located near the rear of
the wire reel stand base. Put the control cable and
the electrode cable under the clamp and install the
screws.
For cables with more than one electrode cable,
leave the junction between the two or more cables
and the single 4/0 stub behind the clamp so that
only the single electrode lead is under the clamp.
3. See Figure A.1. Pass the single electrode cable
through the hole provided in the back corner of the
wire section and fasten it to the conductor block of
the copper strap along the side of the wire drive
unit.
INSTALLATION
A-4 A-4
LN-9 GMA Wire Feeder
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FIGURE A.1 – INPUT CONTROL CABLE AND
ELECTRODE CABLE CONNECTIONS
Page 13
INSTALLATION
A-5 A-5
LN-9 GMA Wire Feeder
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FIGURE A.2 – STRAIN RELIEF CLAMP
CONNECTING THE POWER INPUT CABLE
ASSEMBLY TO THE LN-9F CONTROL
BOX
1. See Figure A.3. Connect the polarized plug of the
K196, K595, or K596 control cable to the mating
MS-type connector on the bottom of the LN-9F
GMA control box.
2. Bolt the electrode lead from the power source to the
electrode lead to the wire feed unit using the nut
and bolt supplied. Insulate the connection with electrical tape.
CONNECTING THE POWER INPUT CABLE
ASSEMBLY TO POWER SOURCES
Turn input supply power to the power source OFF
before connecting the LN-9 GMA or LN-9F GMA wire
feeder.
Connect to an appropriate Lincoln power source as follows:
1. If using a multipurpose source (such as the DC250, DC-400 and DC-600), be sure it is properly
set for the welding process being used. See the
topic
"Making a Test Weld,"
in the
Operation
sec-
tion of this manual.
For terminal strip connections using the K196 power
input cable, connect the input cable to the power
source exactly as specified on the appropriate LN-9
GMA model connection diagram:
Figure A.4 for DC-250, DC-400 and CV-400, CV-500 l
Figure A.5 for DC-600
Figure A.6 for DC-1000
Figure A.7 for Pulse Power 500
Figure A.8 for V300
FIGURE A.3 – LN-9F GMA CONTROL BOX
BOTTOM VIEW
WARNING
Page 14
Figure A.8 is a connection diagram for connecting the
LN-9 GMA to V300 power sources. The connection is
made with a K596 cable assembly, which has an
amphenol connection rather than a terminal strip connection at the power source.
Depending on the power source and process you are
using, the jumpers on the LN-9 GMA voltage board
may have to be changed. As shipped, the LN-9 GMAis
connected for use with the DC-250 DC-400, CV-400,
CV-500-I and DC-600. For other power sources, refer
to the appropriate connection diagram.
NOTE: If you are using the Pulse Power 500, DC650
Pro, or V300 power source, the K442-1 Pulse Power
Filter Kit must be installed in the LN-9 GMA. See the
instructions included with the kit. If you are using the
Invertec V300, the K608-1 Adapter must also be
installed according to the connection diagram and
instructions provided in the Invertec Manual.
INSTALLATION
A-6 A-6
LN-9 GMA Wire Feeder
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Page 15
INSTALLATION
A-7 A-7
LN-9 GMA Wire Feeder
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FIGURE A.4 – CONNECTION OF LN-9 GMA TO DC-250, DC-400, and CV/CVI POWER SOURCES
Above diagram shows electrode connected positive. To change polarity, turn power off, reverse the electrode and work leads at the
power source and position the switch on power source to proper polarity.
* Does not apply to DC-400 below code 9200 with polarity switch.
N.A. Welding cables must be of proper capacity for the current and duty cycle of immediate and future applications.
N.B. Extend lead #21 using #14 AWG or larger insulated wire physically suitable for the installation. An S16586-[ ] remote voltage
sensing work lead is available for this purpose. Connect it directly to the work piece keeping it electrically separate from the welding work lead circuit and connection. For convenience, this extended #21 lead should be taped to the welding work lead. (If the
length of work lead circuit is short, and connections can be expected to be reliable, then control cable lead #21 does not need to
be extended and can be directly connected to terminal #21 on the terminal strip. Note that this is not the preferred connection
because it adds error to the wire feeder voltmeter reading.)
N.C. Tape up bolted connection if lead #21 is extended.
N.D. Connect the control cable ground lead to the frame terminal marked near the power source terminal strip. The power source
grounding terminal (marked and located near the power source input power connections) must be properly connected to elec-
trical ground per the power source operating manual.
N.F. The LN-9 GMA voltage control jumpers must be connected as follows:
White jumper on voltage board to pin “S”.
Blue jumper on voltage board (later units only), or on start board (earlier units), to pin “B”.
*N.G. If lead #21 is to be connected to the terminal strip, connect to the #21 terminal that matches work polarity. This connection must
be changed whenever the electrode polarity is changed.
WARNING
• Turn off input power to the welding
power source using the disconnect
switch at the fuse box before connecting the wire feeder
• Only qualified persons should install,
use or service this machine.
ELECTRIC SHOCK
can kill.
TO LN-9 GMA INPUT CABLE PLUG
Page 16
TO LN-9 GMA INPUT CABLE PLUG
INSTALLATION
A-8 A-8
LN-9 GMA Wire Feeder
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FIGURE A.5 – CONNECTION OF LN-9 GMA TO DC-600 POWER SOURCES
Above diagram shows electrode connected positive. To change polarity, turn power off, reverse the electrode and work leads at the
power source and position the switch on power source to proper polarity.
For optimum performance with the LN-9 GMA, DC-600’s with codes 8288 and above are preferred.
N.B. Welding cables must be of proper capacity for the current and duty cycle of immediate and future applications.
N.C. Extend lead #21 using #14 or larger insulated wire physically suitable for the installation. An S16586-[ ] remote voltage sensing
work lead is available for this purpose. Connect it directly to the work piece keeping it electrically separate from the welding work
lead circuit and connection. For convenience, this extended #21 lead should be taped to the welding work lead. (This extended
#21 lead connection replaces the need to employ the remote work lead accessory on LN-9’s which have a direct work lead jack.)
N.D. Tape up bolted connection.
N.E. Connect the LN-9 GMA control cable ground lead to the frame terminal marked near the power source terminal strip. The
power source must be properly grounded.
N.G. The LN-9 GMA voltage control jumpers must be connected as follows:
White jumper on voltage board to pin “S”.
Blue jumper on voltage board (Later units only) or on start board (Earlier units) to pin “B”.
N.H. For DC-600 Codes below 8200 connect a jumper from “N” to “P” on LN-9 GMA only. There is no NPS terminal strip on codes
above 8200.
ELECTRIC SHOCK
can kill.
• Turn off input power to the welding
power source using the disconnect
switch at the fuse box before connecting the wire feeder
• Only qualified persons should install,
use or service this machine.
WARNING
Page 17
INSTALLATION
A-9 A-9
LN-9 GMA Wire Feeder
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FIGURE A.6 – CONNECTION OF LN-9 GMA TO DC-1000 POWER SOURCES
Above diagram shows electrode connected positive. To change polarity, turn power off, reverse the electrode and work leads at the
power source, position the positive - negative switch on power source to correspond to the polarity of the electrode cable connection.
N.A. Welding cables must be proper capacity for the current and duty cycle of immediate and future applications.
N.B. Extend lead #21 using #14 or larger insulated wire physically suitable for the installation. an S16586 remote voltage sensing work
lead is available for this purpose. Connect it directly to the work piece keeping it separate from the welding work cable connection
to work piece. For convenience, this extended #21 lead should be taped along the welding work cable. (This extended #21 lead
connection replaces the need to employ the remote work lead accessory on any LN-9 GMA which has a direct work lead jack).
N.C. Tape up bolted connection.
N.D. Connect the LN-9 GMA control cable ground lead to the frame terminal marked near the power source terminal strip. The
power source must be properly grounded.
N.E. If using an older automatic control cable with leads #75, #76, #77; connect lead #75 to #75 on terminal strip, connect lead #76 to
#74 on terminal strip, connect lead #77 to #73 on terminal strip.
N.F. The LN-9 GMA voltage control jumpers must be connected as follows:
White jumper on voltage board to pin “S”.
Blue jumper on voltage board (Later units only) or on start board (earlier units) to pin “B”.
N.G. Set the DC-1000 controls as follows:
Set the control switch to “output control remote”. For submerged arc processes, set the mode switch to “C.V. submerged arc”.
For open arc processes, set the mode switch to “C.V. Innershield”.
N.H. Alternative 500 amp positive terminal connection provided on DC-1000 models above code 9500 only.
WARNING
• Turn off input power to the welding
power source using the disconnect
switch at the fuse box before connecting the wire feeder
• Only qualified persons should install,
use or service this machine.
ELECTRIC SHOCK
can kill.
TO LN-9 GMA INPUT CABLE PLUG
Page 18
INSTALLATION
A-10 A-10
LN-9 GMA Wire Feeder
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FIGURE A.7 – CONNECTION OF LN-9 GMA TO PULSE POWER 500 POWER SOURCES
Above diagram shows electrode connected positive. To change polarity, turn power off, reverse the electrode and work leads at the
power source and properly set the feeder polarity switch.
N.A. Welding cables must be of proper capacity for the current and duty cycle of immediate and future applications.
N.B. Extend lead #21 using 14 AWG or larger insulated wire physically suitable for the installation. An S16586-[ ] remote voltage sens-
ing work lead is available for this purpose. Connect it directly to the work piece keeping it electrically separate from the welding
work lead circuit and connection. For convenience, this extended #21 lead should be taped to the welding work lead.
N.C. Tape up bolted connection.
N.D. Connect the control cable ground lead to the frame terminal marked near the power source terminal strip. The power source
grounding terminal (marked and located near the power source input power connections) must be properly connected to electrical ground per the power source Operating Manual.
N.E. Connect control leads t terminal strip as follows:
LN-9: A to 75 B to 77 C to 78
N.F. The LN-9 GMA voltage control jumpers must be connected as follows:
White jumper on voltage board to pin “S”.
Blue jumper on voltage board is not connected to any pin. (Secure loose jumper clear of any possible interference.)
NOTE: For proper pulse welding operating with LN-9:
1. The LN-9 GMA must have an L6084-3 (or higher superseding part number) voltage board installed. (Standard above code
9100.)
2. The Pulse Power Filter board must be installed and connected in the LN-9 per instructions provided with the kit.
3. The pulse current sensor assembly (with looped copper energizer) must be installed. (Standard above code 9100.) Feeder
conversion kits are available for all LN-9 GMA model codes (below 9100 and above 9100).
WARNING
• Turn off input power to the welding
power source using the disconnect
switch at the fuse box before connecting the wire feeder
• Only qualified persons should install,
use or service this machine.
ELECTRIC SHOCK
can kill.
TO LN-9 GMA INPUT CABLE PLUG
Page 19
INSTALLATION
A-11 A-11
LN-9 GMA Wire Feeder
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FIGURE A.8 – CONNECTION OF LN-9 GMA TO V300 POWER SOURCES
N.A. Welding cable must be sized for current and duty cycle of application.
N.B. Diagram shows electrode positive. To change polarity, turn power “OFF”, reverse electrode and work cable at power source. Set
meter polarity switch on rear of invertec to coincide with polarity used. Set LN-9 GMA polarity switch also.
N.C. Install K608-1 adapter in line with P10 to LN-9 GMA voltage board and secure to adjacent harness with wire tie provided. Turn
“start” trimmer on voltage board per instructions in V300 manual.
N.D. For GMAW welding, install Pulse Power Filter Kit K442-1 in LN-9 GMA.
WARNING
• Turn off input power to the welding
power source using the disconnect
switch at the fuse box before connecting the wire feeder
• Only qualified persons should install,
use or service this machine.
ELECTRIC SHOCK
can kill.
ELECTRODE CABLE
TO LN-9 GMA
TO WORK
INVERTEC
POWER SOURCE
WITH 110/115V AUX.
14 PIN
AMPHENOL
CONNECTION
LN-9 GMA WITH
K608-1 AND
K442-1 KITS
K596 REMOTE
CONTROL CABLE
ASSEMBLY
P10,J10'
2
3
4
5
6
7
10
K608-1
DETAIL
530A
521
500
500
524
C
3.9K ohm
P10',J10
2
3
4
5
6
11
11
12
B
533
7
12
Page 20
INSTALLATION
A-12 A-12
LN-9 GMA Wire Feeder
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MACHINE GROUNDING
LN-9 GMA wire feeders are grounded to the power
source through the input cable. The power source
grounding cable must be properly connected to electrical ground. See your power source operating manual
for details.
WORK CABLE CONNECTION
Connect a work lead of sufficient size and length
between the proper output terminal on the power
source and the work. See Table A-1. Be sure the connection to the work makes tight metal-to-metal electrical contact. Poor work lead connections can activate
the grounding lead protector and/or result in poor welding performance.
TABLE A.1 – WORK CABLE SIZES
Current
Copper Work Cable Size, AWG
60% Duty Cycle
Up to 50' length 50'-100' Iength
300 Amps 0 00
400 Amps 00 000
500 Amps 00 000
600 Amps 000 0000
DIRECT WORK LEAD CONNECTION
Lincoln specified procedures give voltage readings
taken between the work and the gun cable brass connection block of the LN-9 GMA. To match these voltage
readings, the connection diagrams show the #21 lead
being extended and connected directly to the work
instead of #21 on the power source terminal strip (or
Dual Process Kit terminal strip). This extended lead
must be connected directly to the work. When using a
Dual Process Kit, you must extend the lead individually for each LN-9 GMA.
As an alternative, LN-9 GMA models are provided with
a quick-connect terminal splice connection in the #21
lead between the input Amphenol connector of the LN9
GMA and its polarity switch. See the LN-9 GMA wiring
diagram. This in-line connection consists of a red insulated male and female .250 x .032 terminal pair located in the lead harness. It runs along the right side of
the wire feed motor inside the control section of the LN9 GMAmodels and in the lead harness at the lower left
corner of the control box (near the input Amphenol) of
the LN-9F models. You may also open this #21 lead
and connect your own direct work lead equipped with a
.250 x .032 female quick-connect terminal to the male
side of the splice. This direct work lead connection
must be tape insulated, strain-relieved, and routed outside the LN-9 GMA control box to be connected directly to the work.
With either direct work lead connection method, the
LN-9 GMA regulates the power source to hold the arc
voltage constant, even with voltage drops in the electrode lead, work lead, or work lead connection. If the
direct work lead becomes disconnected from the work,
the LN-9 GMA wire feeder will stop welding shortly
after the arc is struck. See the topic "
Circuit
Protection and Automatic Shutdown"
in the
Operation
section of this manual.
Page 21
INSTALLATION
A-13 A-13
LN-9 GMA Wire Feeder
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CONNECTING THE GUN CABLE TO
THE WIRE FEEDER
A variety of gun and cable assemblies are available for
the LN-9 GMA models. See the
Accessories
section
of this manual.
Lay the cable out straight. Insert the connector on the
welding conductor cable into the brass conductor block
on the front of the wire drive unit. See Figure A.9. Make
sure the connector is fully seated and tighten the plastic thumbscrew. Keep this connection clean and bright.
Connect the control cable polarized Amphenol plug into
the mating 5-cavity receptacle on the front panel of the
wire drive section.
FOR GMA GUN CABLES:
Install the barbed fitting and union nut to the 5/8-18
female inert gas fitting on the front of the LN-9 GMA
wire drive section. Connect the 3/16" I.D. gas hose
from the gun cable to the barbed fitting.
When you remove the gun, you can easily detach this
fitting by loosening the union nut.
FIGURE A.9 – GUN CABLE CONNECTIONS
Thumbscrew
Page 22
HOOKING UP GMA SHIELDING
GAS
CYLINDER may explode if
damaged.
• Gas under pressure is explosive.
•· Always keep gas cylinders in an
upright position and always keep
them chained to the undercarriage
or a stationary support.
See American National Standard Z-49.1, "Safety in
Welding and Cutting," published by the American
Welding Society.
The user must provide a cylinder of shielding gas, a
pressure regulator, a flow control valve and a hose
from the flow valve to the gas inlet fitting of the LN-9
GMA. See Figure A.10 and install as follows:
1. Connect the supply hose from the gas cylinder flow
valve outlet to the 5/8-18 female inert gas fitting on
the back panel of the LN-9 GMAwire drive section.
2. Install the barbed fitting and union nut to the 5/8-18
female inert gas fitting on the front of the LN-9
GMA. Connect the 3/16 inch (4.8 mm) I.D. gas
hose from the gun to the barbed fitting.
When you need to remove the gun, you can easily
detach this fitting by loosening the union nut.
INSTALLATION
A-14 A-14
LN-9 GMA Wire Feeder
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WARNING
FIGURE A.10 – SHIELDING GAS HOOKUP
Page 23
TABLE OF CONTENTS
- OPERATION SECTION -
Section B-1 Section B-1
LN-9 GMA Wire Feeder
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Operation
Operating Instructions.................................................................................................................B-2
Safety Precautions......................................................................................................................B-2
General Description ....................................................................................................................B-3
Recommended Processes and Equipment.................................................................................B-3
K424 LN-9 GMA 2-Roll and K568-1 LN-9 GMA 4-Roll.........................................................B-3
K436 LN-9F GMA 2-Roll and K538-1 LN-9 GMA 4-Roll ......................................................B-3
DC Constant Voltage Power Sources..................................................................................B-4
Controls and Settings..................................................................................................................B-5
Circuit Protection and Automatic Shutdown.........................................................................B-8
Avoiding Grounding Lead Protector (GLP) Shutdown..........................................................B-8
Drive Roll Installation ................................................................................................................B-10
Changing Drive Rolls for 2-Roll Wire Feeders...................................................................B-10
Changing Drive Rolls for 4-Roll Wire Feeders...................................................................B-12
Wire Loading.............................................................................................................................B-14
Loading a 22 to 30 lb. Reddi-Reel Package.......................................................................B-14
Loading a 10 to 30 lb. Spool ..............................................................................................B-15
Loading 50 to 60 lb. Coils...................................................................................................B-16
Loading and Feeding 13-14 lbs. Innershield Coils.............................................................B-17
Idle Roll Pressure Setting .........................................................................................................B-18
2-Roll Wire Feeders............................................................................................................B-18
4-Roll Wire Feeders............................................................................................................B-18
Making a Test Weld and Adjusting Response and Starting......................................................B-19
Adjust the Power Source....................................................................................................B-19
Adjust the LN9 GMA Controls ............................................................................................B-19
Voltage Control Response..................................................................................................B-20
Starting Characteristics.......................................................................................................B-20
Making a Weld ....................................................................................................................B-21
Procedure at End of Coil...........................................................................................................B-21
Security of Weld Procedure Settings........................................................................................B-21
Page 24
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B-2
B-2
LN-9 GMA Wire Feeder
OPERATING INSTRUCTIONS
Read and understand this entire section of operating
instructions operating the machine.
SAFETY PRECAUTIONS
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts such
as output terminals or internal wiring.
• Insulate yourself from the work and
ground.
• Always wear dry insulating gloves.
FUMES AND GASES can be
dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to remove
fumes from breathing zone.
WELDING SPARKS can cause
fire or explosion.
• Keep flammable material away.
ARC RAYS can burn.
• Wear eye, ear, and body protection.
WARNING
OPERATION
Page 25
GENERAL DESCRIPTION
The LN-9 GMA 2-Roll and 4-Roll semiautomatic wire
feeder models feature the precise "set and forget" digital procedure control and the other welding and operator features pioneered by the original LN-9 models.
In addition, the LN-9 GMA models also have the following advantages for small wire gas metal arc welding with solid or flux cored Outershield®electrodes:
• High speed wire drive with a high torque permanent
magnet motor and tool-less "quickrelease" idle roll
pressure arms, guide tubes and gun cable fastening.
• Factory installed gas solenoid valve with gas inlet and
outlet fittings.
• Adjustable preflow, postflow and burnback timers.
Purge and cold inch switch functions are available.
• For 4-Roll models, a design which provides the additional feeding force. This is required when using gun
cables over 15 ft. long or when wire is being pulled
long distances (for example, bulk packages).
Because the 4-Roll feeder has twice the contact surface, it can also help when feeding softer wires. It
delivers the same or more feeding force as the 2-Roll
with less overall wire deformation. Wire size range,
speed and features are the same as other LN-9 GMA
models.
RECOMMENDED PROCESSES AND
EQUIPMENT
The LN-9 GMA is available in four models:
K424 LN-9 GMA 2-ROLL AND K568-1 LN-9
GMA 4-ROLL
Wire feed unit and all controls completely enclosed in
a single portable enclosure. See Figure B-1.
K436 LN-9F GMA 2-ROLL AND K583-1
LN-9F GMA 4-ROLL
Separate wire feed unit and control box with 16 ft cable
assembly for boom or fixture mounting. See Figure
B.2.
When combined with the broad selection of quality
welding equipment and accessories, the LN-9 GMA
provides a versatile precision welding system to meet
the specific needs of gas metal arc and Innershield®or
submerged arc welding processes. The capabilities of
the LN-9 GMA 2-Roll and 4-Roll are:
Rated wire size range:
.023 through 1/16 solid wire electrode.
.045 through 5/64 Outershield®cored electrode.
.062 through 5/64 lnnershield®cored electrode.
Rated wire speed range:
80 through 980 inches per minute.
(2.03 through 24.9 meters per minute).
OPERATION
B-3 B-3
LN-9 GMA Wire Feeder
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FIGURE B.1 – BASIC LN-9 GMA HOOKUP
FIGURE B.2 – BASIC LN-9F GMA HOOKUP
K196-XXX,
Page 26
DC CONSTANT VOLTAGE POWER
SOURCES
The following welding system power sources are available for use with all LN-9 GMA models:
The Idealarc®DC-250, DC-400, CV-400, CV-500 and,
DC-600 are recommended for use with any LN-9 GMA
model, as well as the Pulse Power 500, Invertec V300,
and DC650 Pro, with the installation of the optional
K442-1 Pulse Power Filter Kit.
OPERATION
B-4 B-4
LN-9 GMA Wire Feeder
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Page 27
OPERATION
B-5 B-5
LN-9 GMA Wire Feeder
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CONTROLS AND SETTINGS
Operator controls for LN-9 GMA models are shown in
Figure B.3. Controls for LN-9F models are shown in
Figure B.4. Refer to these figures and the following
descriptions of the controls.
ELECTRODE POLARITY SWITCH: The polarity
switch is located inside the wire drive section on the
LN-9 GMA model and on the front panel of both the
LN-9F GMA 2-Roll and 4-Roll control box. Set the
switch to the same polarity as the electrode lead connection to the power source. If the switch is not set
for the correct polarity, the wire feeder will stop welding shortly after the arc is struck. See the topic
"Automatic Shutdown"
later in this section of the
manual.
WIRE FEED DIRECTION SWITCH: The direction
switch is located inside the wire drive section on the
LN-9 GMA model and on the front panel of both the
LN-9F GMA 2-Roll and 4-Roll control box. This switch
permits the wire to be fed in either direction when the
trigger is pressed or when using the cold inch switch
feature of the K418 and K419 options. Be sure this
switch is set for forward feed when you are ready to
weld.
HOT-COLD TRIGGER INTERLOCK SWITCH: This
switch is located on the front rail on the LN-9 GMA
model and on the front panel of both the LN-9F GMA
2-Roll and 4-Roll control box. The three-position
switch serves a dual purpose:
1. "Hot-Cold" Wire Feed - In the center position the
wire will be electrically cold when feeding with the
gun trigger. In either the up or down positions the
wire will be "hot" when feeding with the gun trigger.
2. Trigger Interlock Function - In the down position
the trigger interlock will be OFF, allowing the gun
trigger to function in the normal mode. This stops
wire feed and welding when the trigger is released.
In the up position the trigger interlock will be ON.
The trigger interlock feature functions as follows:
a) When you are not welding, the trigger will function
in the normal mode, which feeds only when the
trigger is closed.
b) Once the welding arc has been struck, the gun trig-
ger may be released. Welding will continue until
one of the following occurs:
• The arc is extinguished by quickly pulling the gun
away from the work.
or
• The trigger is again depressed and released.
(This feature is not on earlier versions unless the
L7265-1 PM Power Board has been replaced
with a superceded version.)
Page 28
FIGURE B.3 – WIRE FEEDER CONTROLS FOR LN-9 GMA
OPERATION
B-6 B-6
LN-9 GMA Wire Feeder
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Page 29
OPERATION
B-7 B-7
LN-9 GMA Wire Feeder
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FIGURE B.4 – WIRE FEEDER CONTROLS FOR LN-9F GMA
Page 30
OPERATION
B-8 B-8
LN-9 GMA Wire Feeder
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CIRCUIT BREAKER AND GROUNDING LEAD PROTECTOR (GLP) RESET SWITCH: These protection
circuit devices are located on the front rail of the LN-9
GMA model and bottom panel of the LN-9F models.
See the topic
"Circuit Protection and Automatic
Shutdown"
later in this section of the manual.
DIGITAL METER: A three-digit digital meter is provided to set and monitor the welding procedure. The arc
voltage is displayed in volts and the wire feed speed is
displayed in inches/minute or meters/minute.
METER READING SWITCH, VOLTS AND WIRE
SPEED CONTROLS: This four-position rotary switch
is located to the right of the digital meter on LN-9 GMA
models and to the left of the digital meter on LN-9F
models. When set to the "Volts" position, the meter
reads the arc voltage setting as adjusted by the "Volts"
control. The rated setting range for all the LN-9 GMA
models is 12.0 to 60.0 volts.
The three "Wire Speed" positions include an English
position, for meter readings in inches/minute; and "LO"
and "HI" range metric positions for meter readings in
meters/minute. The wire feed speed setting is adjusted by the "Wire Speed" control. The rated setting
range for all the LN-9 GMA models are 80 to 980 inches/minute (2.03 to 24.9 meters/minute).
When using metric meter readings, set the switch to
"LO" for more precise meter readings up to 393 in/min
(9.99 m/min.). For higher wire feed speeds, the "LO"
position will result in an over-range meter reading of
E.EE which indicates that the "HI" range, with single
decimal place resolution, should be used. Similarly,
EEE will be displayed on the English position if the setting exceeds 999 inches/minute.
The procedure adjustments can be made before or
during the weld. This feature permits the operator to
set the welding voltage and wire speed before welding
and without assistance.
Once set, the control circuits of the LN-9 GMA will continuously monitor the volts and wire speed and correct
any deviation from the set value so there will be negligible change.
Should the range of the power source output voltage be
such that the unit circuit cannot keep the arc voltage as
set, the unit will stop welding shortly after the arc is struck.
See the topic
"Circuit Protection and Automatic
Shutdown"
later in this section of the manual.
SET-ACTUAL PUSHBUTTON: After the weld has
been started, the ACTUAL voltage or wire speed can
be read by pressing the pushbutton to the left of the
meter. The METER READING switch must be set in
the desired position. When the pushbutton is not being
operated, the meter continues to read the SET value.
CIRCUIT PROTECTION AND AUTOMATIC
SHUTDOWN
CIRCUIT BREAKER
The circuit breaker normally trips only when excessive
loading in the wire feed cable or a defective motor or
control component causes an overload. After allowing
a minute for cooling, push in the circuit breaker button
and weld. If it trips again, be sure the wire feed cable
is clean and the proper size for the wire diameter being
fed. If the breaker still trips, look for a defective electrical component. When the circuit breaker is tripped,
the digital meter is off and the trigger circuit will not
operate.
POWER SUPPLY FUSE
The fuse on the PM power board inside the control box
protects the power supply circuit. When the fuse is
blown, the digital meter is off and the trigger circuit will
not operate.
VOLTAGE PC BOARD FUSE
The 1/8 amp fast-blow fuse protects the LN-9 GMA circuitry from damage that may result from a ground, or
case, faulted control lead. If this fuse blows, the LN-9
GMA arc voltage sensing lead circuit will be opened.
See the topic
"Automatic Shutdown"
below.
AVOIDING GROUNDING LEAD PROTECTOR
(GLP)
SHUTDOWN
The frames of all LN-9 GMA wire feed units and drive
motors are grounded to the frame of the power source
by a lead in the control cable. An overload protector
prevents welding current from damaging this lead if the
electrode circuit touches the wire feeder frame while
the gun trigger is pressed.
Page 31
If such a grounding lead fault occurs, the meter will still
be on and will be reading. The trigger circuit will not
operate, however. To release the circuit, press the
"GLP Reset" button. See
Figure B.3 or B.4
for the
location of this button.
The following precautions are recommended to avoid
GLP shutdown:
• Do not allow the electrode to contact the case of the
wire feeder or uninsulated part of its wire reel stand
when the gun trigger is activated.
• Be sure that all work lead connections to the work
make tight metal-to-metal electrical contact.
• Do not allow excess input cable or work cable to be
placed closer than 3 feet to the wire feeder.
• Do not coil excess input cable assembly or use an
uncoiled assembly as shipped from the factory.
Instead, loop excess length back and forth in 3 to 6
foot straight lengths. Coiling the input cable results in
a transformer action between the electrode conductor
cable and ground lead in the multiconductor cable
and the ground lead in the multiconductor control
cable. This can cause current to flow in the ground
lead, which will falsely activate the GLP.
AUTOMATIC SHUTDOWN
If the LN-9 GMA voltage control is unable to supply the
SET value of arc voltage while welding, the automatic
shutdown circuit will activate. This protection circuit
immediately returns the LN-9 GMA control to idle state
within a few seconds after the arc voltage discrepancy
occurs.
Typical causes for the activation of this protective shutdown circuit are as follows:
a) SET value of arc voltage is outside the power
source range.
b) Power source voltage control not set for REMOTE.
c) Misconnection of LN-9 control cable leads to
power source.
d) Incorrect weld polarity connections, or settings, at
the LN-9 GMA or the power source.
e) Lost connection of LN-9 GMA voltage sensing
leads (#67 and #21) between the arc and voltage
control, or a blown 1/8 amp fuse on the Voltage PC
board.
In the case of full range control power sources, such as
the DC-600, this protective shutdown circuit could prevent welding under the conditions of (c), (d), and (e)
above by holding the power source output at minimum.
The power source output might even be too low to
establish an arc.
Although out of range shutdown can occur with all
power sources when working with very low or very high
arc voltages, it is most likely to occur when using the
R3S models with somewhat limited voltage range of
the various taps. For instance, if the R3S-400 triangle
tap setting is for 31 volts, the range of control from the
remote circuit is approximately 7 volts, i.e., 27-1/2 to
34-1/2 volts at nominal input voltage. If the LN-9 GMA
controls are set for 29 volts and the input voltage to the
R3S goes up, it may not be possible for the LN-9 GMA
control circuit to hold the 29 volts. The welding will shut
down. By changing to the 27 volt triangle setting, the
range will be approximately 23-1/2 to 30-1/2 volts, and
at high input voltage there will be sufficient control to
hold the SET arc voltage.
The same general procedure can be used on other
power sources. For example, if the LN-9 GMA keeps
shutting down and the other possible causes have
been checked, adjust the SET voltage higher and/or
lower than the desired voltage. Then you can determine what change in the range controls of the power
source is required to supply the desired voltage.
In some cases, it is also possible to hold the ACTUAL
button pressed while starting the arc. Before the LN-9
GMAshuts down, the actual arc voltage can be read on
the digital meter. Comparing this reading to the SET
reading will tell what change in the range controls of
the power source is required to supply the desired voltage. Should the meter read zero, check the connections of LN-9 GMAsensing leads #21 and #67. Should
the meter read a minus (-) voltage, the polarity connections or settings at the LN-9 GMA or power source
are wrong.
OPERATION
B-9 B-9
LN-9 GMA Wire Feeder
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Page 32
DRIVE ROLL INSTALLATION
CHANGING DRIVE ROLLS FOR 2-ROLL
WIRE FEEDERS
To change drive rolls on a 2-roll wire feeder, refer to
Figure B.5
and perform the following steps.
NOTE: Although an LN-9 GMA model is shown in
Figure B.5, the following procedure also
applies to LN-9F GMA models.
1. Rotate the latch knob on the quick release arm.
2. Remove the hex head screw and clamping collar.
Remove the drive roll from the shaft.
3. The new roll to be installed is stamped for the size
to be fed. An "A" after the size indicates aluminum
wire. Remove the rolls from the kit and wipe them
clean. Wipe the output shaft and locating shoulder
clean.
4. Use the drive key, clamping collar, and hex head
screw to install the roll on the output shaft. Certain
size drive rolls consist of two roll halves, and may
contain a spacer. If the drive roll you are installing
contains a spacer, the spacer fits between the two
halves of the drive roll. Tighten the hex head
screw.
5. Back out the guide tube clamping screws. Remove
the old guide tubes, if installed.
6. Insert the outgoing guide tube (the one with the
plastic insert) into the front hole. If the guide tube
has a non-symmetrical chisel end, the larger radius
must face the drive roll. See
Figure B.5
. Push the
guide tube back as far as it will go and tighten the
clamping screw. Insert the incoming guide tube as
far back as it will go and tighten the clamping
screw. The clamping screws are dog points. When
the guide tubes are properly installed these dog
points will lock into the annular grooves in each of
the guide tubes.
7. Set the idle roll pressure as detailed in the
Idle Roll
Pressure Setting
procedure detailed later in this
section.
OPERATION
B-10 B-10
LN-9 GMA Wire Feeder
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Page 33
CLAMPING
COLLAR
DRIVE
ROLL
HALVES
SPACER
(IF REQ'D)
KEY
OUTPUT
SHAFT
GUIDE TUBE DETAIL
OUTGOING
GUIDE TUBE
INSERT
OUTGOING
GUIDE TUBE
LARGE
RADIUS
DRIVE
ROLL
INCOMING
GUIDE
TUBE
SMALL
RADIUS
IDLE
ROLL
OPERATION
B-11 B-11
LN-9 GMA Wire Feeder
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FIGURE B.5 – INSTALLING DRIVE ROLLS ON A 2-ROLL FEEDER
Page 34
CHANGING DRIVE ROLLS FOR 4-ROLL
WIRE FEEDERS
To change drive rolls on a 4-roll wire feeder, refer to
Figure B.6
and perform the following steps.
NOTE: Although an LN-9 GMA model is shown in
Figure B.6
, the following procedure also
applies to LN-9F GMA models.
1. Remove the gun and cable from the conductor
block on the feeder by loosening the hand screw
and pulling the gun straight out of the block.
2. Open both quick release levers by moving the
levers outward and pulling them toward you.
3. Loosen the thumb screws holding the guide tubes
in place. Remove the incoming and outgoing
guide tubes, if installed.
4. Remove the hex head screws and clamping collars
from the output shafts. Remove the drive rolls and
middle guide tube, if installed.
5. The new rolls to be installed are stenciled with the
wire size that will be fed. An "A" after the number
indicates aluminum wire. Remove the rolls from
the kit and wipe them clean. Wipe the output
shafts and locating shoulders clean.
6. Install one roll onto either output shaft using the
drive key, clamping collar, and hex head screw.
Certain size drive rolls consist of two roll halves,
and may contain a spacer. If the drive roll you are
installing contains a spacer, the spacer fits
between the two halves of the drive roll. Tighten
the hex head screw.
7. Install the middle guide tube, but do not tighten at
this time. When installing a 0.035" middle guide
tube the larger radius should be aligned towards
the drive roll. Slide the guide tube up against the
drive roll.
8. Install the second drive roll on the remaining shaft
the same way as the first. Center the middle guide
tube between the rolls and tighten the thumbscrews holding it in place.
9. Close and latch both quick release levers.
10. Slide the incoming guide tube into the rear hole of
the gearbox until it almost touches the drive roll
and guide tube. Tighten the thumbscrew to hold it
in place.
11. Install the outgoing guide tube into the front hole of
the gearbox (through the conductor block) and
tighten the thumb screw. The 0.035 in. outgoing
guide tube should have the larger radius oriented
toward the drive roll. For proper installation of the
outgoing guide tube insert, refer to
Figure B.6.
12. Be certain that the guide tubes do not touch the
drive rolls or idle rolls. If they do touch, readjust
them and tighten in place.
OPERATION
B-12 B-12
LN-9 GMA Wire Feeder
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Page 35
OPERATION
B-13 B-13
LN-9 GMA Wire Feeder
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FIGURE B.6 – INSTALLING DRIVE ROLLS ON A 4-ROLL FEEDER
KEY
OUTPUT
SHAFT
CLAMPING
COLLAR
DRIVE
ROLL
HALVES
SPACER (IF
REQUIRED)
KEY
GUIDE TUBE DETAIL
OUTGOING
GUIDE TUBE
INSERT
OUTPUT
SHAFT
OUTGOING
GUIDE TUBE
LARGE
RADIUS
DRIVE
ROLL
IDLE
ROLL
SMALL
RADIUS
MIDDLE
GUIDE
TUBE
Page 36
OPERATION
B-14 B-14
LN-9 GMA Wire Feeder
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WIRE LOADING
Loading a 22 to 30 Lb. (10 to 14 kg) Readi-Reel
Package Using the Molded Plastic K363-P
Readi-Reel Adapter:
The Spindle should be located in the LOWER mounting hole.
1) Depress the Release Bar on the Retaining Collar and
remove it from the spindle. NOTE: Earlier spindles
used a threaded collar. See Figure B.7a or B.7b.
2) Place the Adapter on the spindle.
3) Re-install the Retaining Collar. Make sure that the
Release Bar “pops up” and that the collar retainers
fully engage the retaining groove on the spindle.
4) Rotate the spindle and adapter so the retaining
spring is at the 12 o'clock position.
5) Position the Readi-Reel so that it will rotate in a
direction when feeding so as to be de-reeled from
the bottom of the coil.
6) Set one of the Readi-Reel inside cage wires on the
slot in the retaining spring tab.
7) Lower the Readi-Reel to depress the retaining
spring and align the other inside cage wires with the
grooves in the molded adapter.
8) Slide the cage all the way onto the adapter until the
retaining spring "pops up" fully.
Check to be sure the Retaining Spring has fully
returned to the locking position and has SECURELY
locked the Readi-Reel Cage in place. Retaining Spring
must rest on the cage, not the welding electrode.
___________________________________________
9) To remove Readi-Reel from Adapter, depress
retaining spring tab with thumb while pulling the
Readi-Reel cage from the molded adapter with both
hands. Do not remove adapter from spindle.
FIGURE B.7a (Threaded Locking Collar)
FIGURE B.7b (Retaining Collar)
WARNING
2 IN. O.D. SPINDLE
ADAPTER
RETAINING SPRING
BRAKE
HOLDING
PIN
GROOVES
READI-REEL
INSIDE CAGE WIRES
THREADED
LOCKING
COLLAR
Page 37
LOADING A 10 TO 30 LB. (4.5 TO 14 KG)
SPOOL (12" DIAMETER) OR 13 - 14 LB.
(6 KG) INNERSHIELD COIL:
The Spindle should be located in the LOWER mounting hole.
(For 8" (200 mm) spools, a K468 spindle adapter must
first be slipped onto spindle.)
(For 13-14 lb. (6 Kg) Innershield coils, a K435 Coil
Adapter must be used).
1) Depress the Release Bar on the Retaining Collar
and remove it from the spindle. NOTE: Eariler spindles used a threaded collar.
2) Place the spool on the spindle making certain the
spindle brake pin enters one of the holes in the back
side of the spool. Be certain the wire comes off the
reel in a direction so as to de-reel from the bottom
of the coil.
3) Re-install the Retaining Collar. Make sure that the
Release Bar “pops up” and that the collar retainers
fully engage the retaining groove on the spindle.
LOADING A 50-60 LB. (22.7-27.2 KG.) COIL
USING K1504-1 COIL REEL:
(For 50-60 lb Readi-Reels a K438 Readi Reel Adapter
must be used.)
The Spindle must be located in the UPPER mounting
hole.
1. With the K1504-1 Coil Reel mounted on to the 2"
(51 mm) spindle (or with reel laying flat on the floor)
loosen the spinner nut and remove the reel cover.
2. Before cutting the tie wires, place the coil of electrode on the reel so it unwinds from the bottom as
the reel rotates.
3. Tighten the spinner nut against the reel cover much
as possible by hand using the reel cover spokes for
leverage. DO NOT hammer on the spinner nut
arms.
4. Cut and remove only the tie wire holding the free
end of the coil. Hook the free end around the rim of
the reel cover and secure it by wrapping it around.
Cut and remove the remaining tie wires.
FEEDING ELECTRODE AND BRAKE ADJUSTMENT
1. Turn the Readi-Reel or spool until the free end of
the electrode is accessible.
2. While tightly holding the electrode, cut off the bent
end. Straighten the first six inches. Cut off the first
inch. (If the electrode is not properly straightened,
it may not feed or may not go into the outgoing
guide tube, causing a "birdnest.")
3. Insert the free end through the incoming guide
tube.
4. Press the gun trigger or "cold inch" (if used) and
push the electrode into the drive roll.
USE THE "COLD" TRIGGER SWITCH POSITION, OR
"COLD INCH" OPTION WHEN LOADING. WHEN
INCHING WITH A"HOT" GUN TRIGGER, THE ELECTRODE AND DRIVE MECHANISM ARE ALWAYS
"HOT" TO WORK AND GROUND AND COULD
REMAIN "HOT" SEVERAL SECONDS AFTER THE
GUN TRIGGER IS RELEASED.
5. Inch the electrode through the gun.
6. Adjust the brake tension with the thumbscrew on
the spindle hub, until the reel turns freely but with
little or no overrun when wire feeding is stopped.
Do not overtighten.
OPERATION
B-15 B-15
LN-9 GMA Wire Feeder
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WARNING
Page 38
LOADING 50 AND 60 LB. COILS ON 1”
SPINDLE (K299 or K303 Wire Reel Stand)
ADJUSTABLE WIRE REEL BRAKE
The mount for standard 50 and 60 pound electrode
coils includes a two position brake assembly.
Generally the brake should be a the inner position
(nearest to the wire reel shaft) for wire feed speeds
below 400 in/min. It should be at the outer position for
the faster wire speeds often used when feeding small
diameter electrode.
To adjust the brake position, remove the wire reel. Pull
the cotter pin that holds the brake shoe to the arm,
move the shoe and replace the cotter pin. Do not bend
the cotter pin - it is held in place by a friction fit.
LOADING A 50 OR 60 LB. COIL
1. To remove the wire reel from its shaft, grasp the
spring loaded knob and pull it out. This straightens
the knob so that it seats into the shaft when
released. Remove the reel.
2. Lay the reel flat on the floor, loosen the spinner nut
and remove the cover plate.
3. Before cutting the tie wires, place the coil of electrode on the reel so that it unwinds as the reel
rotates clockwise.
a) Be sure the coil is placed so that the spring loaded
arms will not interfere with the later removal of the
coil tie wires. See Figure B.8.
b) When loading 0.030, 0.035 and 0.045" electrode,
be certain the coil is placed on the reel so that the
spring loaded arms are at the center of the slots in
the cardboard coil liner. This provides the positive
compression of the coil sides needed for trouble
free wire feeding. See Figure B.8.
c) Put the cover plate on the reel so that the four arms
of the cover straddle and are in line with the spring
loaded arm of the reel.
4. Tighten the cover as much as possible by hand.
DO NOT hammer on the spinner nut arms.
5. Cut and remove only the tie wire holding the free
end of the coil. Insert the free end into one of the
holes in the cover and secure it by bending it back.
Cut and remove the remaining tie wires.
Always be sure the free end of the coil is securely held
while the tie wires are being cut and until the wire is
feeding through the drive rolls. Failure to do this will
result in "backlashing" of the coil, which may tangle the
wire. A tangled coil will not feed; therefore it must
either be untangled or discarded.
6. Replace the reel on the wire feeder. Grasp the
shaft knob, pull it out and swing it across the reel
hub, locking the reel in place.
7. The mount for standard 50 and 60 pound electrode
coils includes a two-position brake assembly.
Generally the brake should be at the inner position
(nearest to the wire reel shaft) for wire feed speeds
below 400 in/min. It should be at the outer position
for the faster wire speeds often used when feeding
small diameter electrode.
To adjust the brake position, remove the wire reel.
Pull the cotter pin that holds the brake shoe to the
arm, move the shoe and replace the cotter pin. Do
not bend the cotter pin - it is held in place by a friction fit.
OPERATION
B-16 B-16
LN-9 GMA Wire Feeder
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SPINNER
NUT
COVER
PLATE
COIL
REEL
SLOTS
CARDBOARD
COIL
LINER
TIE WIRE
SPRING
LOADED
ARM
FIGURE B.8 – LOADING A 50 OR 60 LB. COIL
CAUTION
Page 39
FEEDING ELECTRODE AND BRAKE ADJUSTMENT
1. Turn the reel until the free end of the electrode is
accessible.
2. While tightly holding the electrode, cut off the bent
end. Straighten the first 6 inches.
3. Cut off the first inch. Insert the free end through
the incoming guide tube.
4. Insert the free end through the incoming guide
tube.
5. Press the gun trigger or “cold inch” (if used) and
push the electrode into the drive roll. (If the electrode is not properly straightened, it may not feed
or may not enter the outgoing guide tube, causing
a "birdnest.")
6. Inch the electrode through the gun.
USE THE "COLD" TRIGGER SWITCH POSITION, OR
"COLD INCH" OPTION WHEN LOADING. WHEN
INCHING WITH A"HOT" GUN TRIGGER, THE ELECTRODE AND WIRE FEEDING SYSTEM ARE ALWAYS
"HOT" TO WORK AND GROUND AND COULD
REMAIN "HOT" SEVERAL SECONDS AFTER THE
GUN TRIGGER IS RELEASED.
LOADING AND FEEDING 13-14 LB.
INNERSHIELD COILS (K378 REEL
MOUNTING STAND)
The K378 small mounting stand for the 14 pound
Innershield coil does not have an adjustable brake. It
has a fixed drag built into the reel spindle.
To load a 14 pound coil:
1. Remove the snap-on lid from the plastic canister.
2. Remove the center clamping nut and the cover
plate from the wire reel.
3. Unpack the 14-pound coil of wire. Be sure not to
bend the side tangs of the coil liner. Straighten any
tangs that may have been bent.
4. Remove the start end of the coil from its holding
slot in the coil liner, cut off the bent end, straighten
the first six inches, and cut off the first inch. (If the
electrode is not properly straightened, it may not
feed or may not go into the outgoing tube, causing
a "birdnest.") Thread it through the canister wire
feed liner until about four inches of electrode are
exposed.
5. Place the coil onto the disc support.
6. Replace the front reel cover and center clamping
nut, keep the reel from turning and tighten the
clamping nut securely.
7. Thread the exposed end of the electrode into the
wire feeder until it touches the drive rolls. Actuate
the gun trigger, and feed the electrode through the
system.
OPERATION
B-17 B-17
LN-9 GMA Wire Feeder
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WARNING
Page 40
OPERATION
B-18 B-18
LN-9 GMA Wire Feeder
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IDLE ROLL PRESSURE SETTING
The idle roll pressure is set at the factory backed out
two turns from full pressure for 2-roll feeders, three
turns from full pressure for 4-roll feeders. This is an
approximate setting. For small wire sizes and aluminum wire, the optimum idle roll pressure varies with
type of wire, surface condition, lubrication and hardness. The optimum idle roll setting can be determined
as follows:
2-ROLL WIRE FEEDERS
1. Press the end of the gun against a solid object that
is electrically isolated from the welder output and
press the gun trigger for several seconds.
2. If the wire "birdnests," jams or breaks at the drive
roll, the idle roll pressure is too great. Back the
pressure setting out 1/2 turn, run new wire through
the gun, and repeat step 1. See Figure B.9.
3. If the only result is drive roll slippage, loosen the
gun cable clamping screw in the gearbox conductor block and pull the gun cable forward about six
inches. There should be a slight waviness in the
exposed wire. If there is no waviness, the pressure
is too low. Increase the pressure setting 1/4 turn,
lock the gun cable in place and repeat steps 1 and 2.
4-ROLL WIRE FEEDERS
1. Release the incoming idle roll and perform the
pressure setting procedure for two-roll wire feeders
to set outgoing idle roll pressure.
2. After the outgoing pressure is set, determine how
many turns away from full pressure the setting is.
3. Set both idle roll tensions to this setting. Engage
both idle rolls before welding. For most applications, best wire feeding will occur when both idle
roll pressures are set the same.
PRESSURE
ADJUSTMENT
KNOB
FIGURE B.9 – IDLE ROLL PRESSURE SETTING
FOR TWO-ROLL FEEDERS
Page 41
MAKING A TEST WELD AND
ADJUSTING LN-9 GMA RESPONSE
AND STARTING CHARACTERISTICS
ADJUST THE POWER SOURCE
DC-250, DC-400, or DC-600
1. Connect electrode lead to terminal of desired
polarity.
2. Set toggle switch to same polarity as the electrode
cable connection.
3. Set toggle switch to "Output Control Remote."
4. Set mode switch to the desired position for the
process to be used.
CV-400, CV-500-I
1. Connect electrode lead to terminal of desired
polarity.
2. Connect #21 control lead to the work polarity terminal (+21 or -21), at the terminal strip, matching
the same polarity as the work cable connection.
3. Set toggle switch to "Output Control Remote."
PULSE POWER 500, DC650 PRO, V300
Refer to each machine Instruction Manual. The LN-9
GMA requires the K442-1 Pulse Power Filter Kit. (See
the
Accessories
section of this manual.)
ADJUST THE LN-9 GMA CONTROLS
1. Set the "Electrode Polarity" switch to same polarity
as the electrode lead.
2. Check that "Feed Direction" is set to forward.
3. Set the "Trigger Interlock" switch as desired.
4. Set the "Meter Reading" switch to "Wire Speed"
and adjust the "Wire Speed" rheostat so the meter
reads the desired wire feed speed.
5. Set the "Meter Reading" switch to "Volts" and
adjust the "Volts" rheostat so the meter reads the
desired arc voltage. IMPORTANT: Make certain
this setting is within the voltage output range of the
power source setting.
6. Load the LN-9 GMA with electrode.
OPERATION
B-19 B-19
LN-9 GMA Wire Feeder
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Page 42
VOLTAGE CONTROL RESPONSE
The LN-9 GMAis provided with selectable voltage control response. Proper setting depends on the power
source and process being used. Refer to the appropriate power source connection diagram for the proper
connection of the jumpers located on the LN-9 GMA
Voltage Board.
To change the voltage control response:
a) Turn OFF the control power to the LN-9 GMAat the
power source.
b) Remove the screws holding the control section
cover in place and swing open.
c) Position the jumper plugs on the Voltage Board
according to the appropriate power source connection diagram.
d) Reassemble.
STARTING CHARACTERISTICS
SELECT ACCELERATION
The LN-9 GMA models can provide optimum starting
for different processes. The wire feeder is designed
to start with two different speeds of controlled acceleration. As shipped, it is connected for fast acceleration,
which is the best for most open arc procedures.
However, the slower acceleration may be more desirable for long stickout applications and most submerged
arc procedures. If the electrode being used does not
give satisfactory starting because of "stubbing" or
"blasting off," slower acceleration can be obtained by
modifying the LN-9 GMA models as follows:
a) Turn OFF the control power to the LN-9 GMAat the
power source.
b) Remove the screws holding the control section
cover in place and swing it open.
c) On machines having an L7253 Control PC board,
move the jumper plug on the PM Control PC board
from pin "F" to pin "S."
On machines having an L10068 Control PC board,
set the DIP switch on the PM Control PC board to
the “S” position.
d) Reassemble.
START VOLTAGE TRIM
The start voltage is the voltage provided by the welding
power source before establishing the welding arc. This
start voltage setting is a function of the open circuit
voltage characteristic of the power source, the SET
value of the weld voltage, and the start voltage trimmer
(R41) setting on the LN-9 Voltage PC Board. As set at
the factory, the start voltage trim level is typically about
20% higher than the LN-9 GMA SET level. This generally gives good starting for steel cored and MIG
processes using CO2or Argon/CO2blended shielding
gas. If you are using "hotter" gases (such as
Argon/Oxygen blends) and other processes (such as
stainless steel MIG), arc flaring may occur at start,
which requires lowering the start voltage trim as follows:
a) Turn off the control power to the LN-9 GMA at the
power source.
b) Remove the screws holding the control section
cover in place and swing it open.
c) On the voltage board, locate trimmer R41 (below
R40 next to the 1/8 amp fuse) and labeled START.
d) The slot on the START trimmer is marked with a
red seal for factory setting. To decrease the factory setting, turn the slot CCW (opposite to the
labeled arrow direction).
NOTE: If the start trim is set too low, stubbing may
occur at start, requiring increasing the START
trimmer by turning the slot CW (in the direction of the labeled arrow).
e) Re-assemble.
RUN-IN FEATURE
On new machines (above code 10350) a “Run-in” trimmer, labeled “RUN-IN,” is provided on the new L100681 Control PC board.
This trimmer can be used to set the run-in wire feed
speed as a percentage of the weld speed. When the
trimmer is turned fully counterclockwise, the run-in
speed is about 5% of the weld speed. When the trimmer is turned fully clockwise, the run-in speed is equal
to the weld speed. To increase the run-in speed, turn
the trimmer clockwise; and to decrease the run-in
speed, turn the trimmer counterclockwise.
The factory setting of the run-in trimmer is about 20%.
The trimmer should be set lower if arc starting tends to
stub or blast, and it should be set higher if the arc tends
to flare up. When the Actual button is pressed, the
actual speed setting can be viewed on the digital speed
meter for two seconds after closing the trigger or the
cold inch switch.
OPERATION
B-20 B-20
LN-9 GMA Wire Feeder
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Page 43
MAKING A WELD
1. Inch the electrode through the gun and cable and
then cut the electrode within approximately 3/8" of
the end of the contact tip for solid wire and within
approximately 3/4" of the extension guide for cored
wire.
2. Connect the work cable to the metal to be welded.
The work cable must make good electrical contact
to the work. The work must also be grounded as
stated in the Safety section at the beginning of this
manual.
3. Be sure the welding power source and the shielding gas supply are turned on.
4. Position the electrode over the joint. The end of
the electrode should be slightly over the joint.
5. Lower the welding helmet, close the gun trigger
and begin welding. Hold the gun so that the contact tip to weld distance gives the correct electrical
stickout as required for the procedure being used.
6. To stop welding, release the gun trigger and then
pull the gun away from the work after the arc goes
out.
PROCEDURE AT END OF COIL
When the wire on the reel is used up, follow this procedure for removing the old wire from the conductor
cable and loading a new reel.
1. Cut the end of the electrode off at the gun end. Do
not break it off by hand since this puts a slight bend
in the wire and makes it difficult or impossible to
pull it back through the nozzle.
2. Uncouple the gun conductor cable from the wire
drive unit.
3. Lay the cable out straight.
4. Using pliers to grip the wire, pull it out of the cable
from the connector end. Do not pull it from the gun
end.
5. Put the conductor cable back on the wire drive unit
after the electrode has been removed.
6. Load a new reel of wire and feed it through the
cable as described earlier in this section.
SECURITY OF WELD PROCEDURE
SETTINGS
There are two ways to prevent or limit unauthorized
readjustment of the LN-9 GMA voltage and wire feed
speed controls.
1. Once the procedure is set, the security panel of the
LN-9 GMA can be locked to prevent access to the
control knobs.
2. The control range of the procedure control knobs
can be limited to either about 3% or about 15% of
the full range control by installing a knob rotation
stop screw to either or both of the control knobs.
This stop screw is installed in the following manner:
a) Turn off the input power to the LN-9 GMA unit.
b) Loosen the knob set screw and remove the
control knob and the felt seal located behind
the knob.
c) Remove the control potentiometer locknut and
fiber spacer, then open the control panel and
remove the potentiometer from the panel.
d) Install a 1/2" long, pan or round head, #4 sheet
metal screw into the 0.10" dia. hole located
.40" from the center of the potentiometer hole
so that the head is on the back side of the
panel (inside the control box).
e) Remount the control potentiometer with the
fiber spacer under the locknut, then close and
secure the control panel.
f) Replace the felt seal around the fiber spacer
so that the #4 screw protrudes between the
fiber spacer and the felt seal.
g) Turn on the input power to the LN-9 GMA unit
and set the desired procedure by rotating the
potentiometer shaft.
h) Carefully replace the control knob so that the
#4 screw inserts into the center of the shorter
length channel on the back of the knob for
about 3% of the total range of control, or the
center of the longer length channel for about
15% of the total range of control.
i) With finger pressure on the knob against the
felt seal, carefully retighten the knob set screw.
NOTE: Steps g) through i) will have to be repeated if
you want to change the set procedure to a
value outside the selected 3% or 15% control
range limit.
OPERATION
B-21 B-21
LN-9 GMA Wire Feeder
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Page 44
NOTES
B-22 B-22
LN-9 GMA Wire Feeder
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Page 45
TABLE OF CONTENTS
- ACCESSORIES SECTION -
Section C-1 Section C-1
LN-9 GMA Wire Feeder
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Accessories
Auxiliary Equipment Contacts.....................................................................................................C-2
Optional Equipment and Accessories .........................................................................................C-2
Power Input Cable Assemblies (K196, K595, K596)............................................................C-2
Wire Reel Stands and Mountings.........................................................................................C-2
Gun and Cable Assemblies..................................................................................................C-5
Wire Feeder Accessories.....................................................................................................C-5
Drive Roll and Guide Tube Kits............................................................................................C-9
Page 46
AUXILIARY EQUIPMENT CONTACTS
The power for 115 volt AC auxiliary equipment can be
obtained from the terminals inside the LN-9 GMA control box. The contacts are “hot” whenever the trigger is
pressed or the unit is welding. The current draw of this
circuit must not exceed 1/4 ampere.
TURN THE INPUT POWER TO THE POWER
SOURCE OFF AT THE DISCONNECT SWITCH
BEFORE PERFORMING THE FOLLOWING WORK.
LN-9 GMA MODEL:
Install 1/4” quick connect terminals to the leads from
the auxiliary equipment. Route the leads to the terminals marked #32A and #7 which come through the rectangular hole in the control section sheet metal near
the wire feed motor.
LN-9F GMA 2-ROLL AND 4-ROLL MODELS:
Install terminals for #6 screws to the leads from the
auxiliary equipment. Route the leads to the terminals
#32A and #7 on the terminal strip on the inside bottom
of the control box.
NOTES:
1. The K418 and K419 burnback timer does not delay
the opening of the auxiliary equipment contacts. If
you want to continue power to auxiliary equipment
during the burnback time, this can be accomplished only if you are using an R3S, DC-400 or
DC-600 power source. Connect the 115 volt AC
auxiliary equipment leads to #4 and #31 on the
power source terminal strip. The auxiliary equipment power requirements should not exceed 15
watts.
This alternate connection cannot be used with the
DC-250 or CV-400, 500-I Power Sources.
2. If the LN-9 GMAgas solenoid valve is not required,
the gas solenoid terminals (#32A and #7A) may be
used in conjunction with the K418 GMATimer Kit to
obtain pre-weld and/or post-weld timing functions
for 115V AC auxiliary equipment. However, the
gas solenoid must be disconnected and the auxiliary equipment current draw must not exceed 1/4
ampere.
OPTIONAL EQUIPMENT AND
ACCESSORIES
POWER INPUT CABLE ASSEMBLIES
(K196, K595, K596)
Required to connect wire feeder to power source.
Includes multiconductor control cable and the proper
size electrode cable for the welding current to be used.
Specify length and maximum welding current.
• K196 Input Cable Assemblies - For power sources
with terminal strip wire feeder connections and stud
output terminals.
• K595 Input Cable Assemblies - For power sources
with MS-type (Amphenol) wire feeder receptacle and
stud output terminals.
• K596 Input Cable Assemblies - For power sources
with MS-type (Amphenol) wire feeder receptacle and
Twist-Mate™ output connectors.
WIRE REEL STANDS AND MOUNTINGS
50-60 LB. WIRE REEL MOUNTING STAND (K303)
The assembly includes a framework to which is
attached the 50-60 lb. wire reel, a mounting spindle, a
dust shield, a lift bail, and a cable clamp for fastening
the input cable assembly. It is easily mounted to the
basic wire feed unit by three bolts. The reel mounting
spindle is the pull knob type with a built-in brake.
The brake pad is adjustable for proper braking at low
or high wire feed speeds.
50-60 LB. READI-REEL®MOUNTING STAND
(K445)
The assembly includes a framework to which is
attached a 2" O.D. spindle with adjustable brake and
50-60 lb. Readi-Reel Adapter. Includes a lift bail and
cable clamp for fastening the input cable assembly,
and easily mounts to the LN-9 GMA feeder. Does not
include dust shield.
Can also be used for up to 60 lb. spools with 2" I.D.
ACCESSORIES
C-2 C-2
LN-9 GMA Wire Feeder
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WARNING
Page 47
ATTACHING THE WIRE REEL STANDS
The mounting hardware for mounting the stands is
included with the LN-9 GMA. Screws and washers are
inserted in their respective mounting holes. To connect:
1. Remove the three 3/8 in. hex head bolts from the
back of the wire feed unit.
2. Place the wire reel mounting stand mounting
bracket in position against the back of the wire feed
unit.
3. Replace and tighten the hex head bolts. The long
screw and plain washer go into the top hole.
WIRE REEL DOOR KIT
Mounts to K303 or to K445 equipped with an S14543
dust shield housing kit, to completely enclose wire
reels against extremely dusty and dirty environments.
Includes a hinged door and sliding bottom seal. Install
the door according to instructions included with the kit.
SPINDLE FOR READI-REELS AND 2" I.D. SPOOLS
(K162-H*)
(60 Lb. Maximum Capacity)
The 2" O.D. spindle kit is for use with the K303. The
shaft for the standard 50-60 pound wire coils is
removed from the mounting framework, and the K162H
is installed in its place. Includes an easily adjustable
friction brake for control of overrun.
When used with Readi-Reels, a Readi-Reel Adapter is
required.
When used with 8" O.D. spools, a K468 Spindle
Adapter is available.
14 Lb. lnnershield coils can be mounted to the spindle
using the K435 Adapter.
* Replaces the K162 30 Lb. Spindle Kit.
Install the spindle according to instructions included
with the kit:
K162 - 30lb (13.6 kg) – M14573 Mounting instructions
K162H - 60 lb (27.2 kg) – M15241 Mounting instructions
DO NOT USE COILS OR SPOOLS HEAVIER THAN
30 LBS. ON THE ORIGINAL K162 SPINDLE.
READI-REEL ADAPTERS
K363-P Adapts Lincoln Readi-Reel coils of electrode
(30 lb. and 22 lb.) to a 2" spindle. One-piece construction. Made from a durable molded plastic. Designed
for easy loading; adapter remains on spindle for quick
changeover. Included with K377 small mounting stand.
K438
Adapts 50-60 lb. Lincoln Readi-Reel coils to a
K162-H spindle, or similar 2 inch spindle suitable for 60 lb.
spools. Two-piece construction made from a durable
flame retardant molded plastic. Designed for minimum
loading downtime, the coils easily load with inside adapter
half on spindle. Four twist latches lock adapter halves
together. Included with K445 50-60 lb. Readi-Reel stand.
60 LB. (27.2 KG) COIL ADAPTER (K1504-1)
Permits 50-60 lb. (22.7-27.2 Kg) coils to be mounted to
a 2" (51mm) spindle.
SMALL MOUNTING STAND FOR READI-REEL
COILS OR 2" I.D. SPOOLS (K377)
(30 Lb. Maximum Capacity)
This assembly includes a small frame to which is
attached a wire reel spindle similar to the K162 spindle.
The unit is supplied with the K363 Readi-Reel Adapter
for use with the Lincoln 22-30 lb. Readi-Reel Electrode
Coils. Without the adapter the unit is capable of handling up to 30 lb. spools with a 2 " I.D., a 12" max. O.D.,
and a 4 " width. For spools with an 8" O.D., a K468
Spindle Adapter is available.
14 lb. lnnershield coils can be mounted to the spindle
using the K435 Adapter. The spindle has an easily
adjustable braking system.
SMALL MOUNTING STAND FOR 13-14 LB. INNERSHIELD COILS (K378)
This assembly includes the same smaller frame as
used in the K377 and a fully enclosed canister system
for de-reeling of the 14 pound coil. This system has a
fixed brake for the 14 pound coil.
50-60 LB. WIRE REEL ASSEMBLY FOR
CUSTOMER MOUNTING (K299)
This assembly is available only when ordering either
the LN-9F GMA 2-Roll or 4-Roll model. It includes a
50-60 lb. wire reel, spindle shaft, adjustable brake,
insulation and mounting hardware.
Install the assembly according to instructions included
with it.
ACCESSORIES
C-3 C-3
LN-9 GMA Wire Feeder
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CAUTION
Page 48
UNIVERSAL WIRE REEL STAND (K1524-1)
Includes a 2" (51mm) O.D. Spindle with adjustable
brake and two locations for mounting the spindle to
allow for the mounting of 50 - 60lb, 10 - 30 lb, 13 - 14lb,
and 8" O.D. coils with proper spindle adapters. (See
OPERATION section) Capable of being mounted on
the top of a suitable power source or surface without
the need for any other mounting kit. Optional features
available for this stand include:
• K1555-1 insulated lift bale
• K1556-1 caster kit
• K1557-1 swivel platform.
K1551-1 Insulated Lift Bale: Provides a bolt on lift
bale with an electrically insulated lift hook.
K1556-1 Caster Kit: Comes with 4 light duty 2" O.D.
casters which mount in place of the rubber feet on the
wire stand. Use in light duty applications where portability is required. Can be used in combination with the
K1557-1 swivel platform.
K1557-1 Swivel Platform: Allows for the mounting of
the wire feeder reel stand assembly on top of a suitable
power source if the need for the wire feeder reel stand
assembly to swivel is desired. Also has mounting
holes in the base feet for mounting to any surface that
it can be fastened to. Comes with a rotating tool tray
to hold gun tips, guide tubes, drive rolls, etc. Will work
in combination with the K1556-1 caster kit.
ACCESSORIES
C-4 C-4
LN-9 GMA Wire Feeder
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Page 49
WIRE FEEDER ACCESSORIES
BURNBACK TIMER KIT (K419)
Provides a precise control of the electrode burnback
at the end of the weld. Prevents crater sticking and
provides proper stickout for starting the next weld.
Recommended especially when welding with small
(0.023-1/16") diameter wire at high wire feed speeds.
Also includes a cold inch switch. (Can be installed
only in GMA models.)
Install the kit according to the M15060 instructions
included with the kit.
ACCESSORIES
C-5 C-5
LN-9 GMA Wire Feeder
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GUN AND CABLE ASSEMBLIES
A variety of standard Lincoln and Magnum gun and
cable assemblies are available for the LN-9 GMA in
10 ft., 12 ft. and 15 ft. cable lengths. Choose the gun
and cable assembly to suit the LN-9 GMA welding
application and wire size. See Table C-1.
TABLE C.1 – LN-9 GMA GUN AND CABLE ASSEMBLIES
60% Duty
Process Model Electrode Rating
Gas Metal Arc (GMA) K426 .035-.052” (0.9-1.3 mm) solid 350 amps
.045-5⁄64” (1.1-2.0 mm) cored 350 amps
K427 .045-1⁄16” (1.1-1.6 mm) solid 500 amps
1
⁄16-5⁄64” (1.6-2.0 mm) cored 500 amps
Magnum K470
(1)
.035-1⁄16” (0.9-1.6 mm) solid 300 amps
.035-5⁄64” (0.9-2.0 mm) cored 300 amps
Magnum K471
(1)
.035-1⁄16” (0.9-1.6 mm) solid 400 amps
.035-5⁄64” (0.9-2.0 mm) cored 400 amps
Magnum K478
(2)
.035-1⁄16” (0.9-1.6 mm) solid 300 amps
.035-5⁄64” (0.9-2.0 mm) cored 300 amps
Magnum K479
(2)
.035-1⁄16” (0.9-1.6 mm) solid 400 amps
0.35-5⁄64” (0.9-2.0 mm) cored 400 amps
Innershield
®
K126 .068-5⁄64” (1.7-2.0 mm) Innershield 350 amps
K115
5
⁄64” (2.0 mm) lnnershield 450 amps
K206
(3)
.068-5⁄64” (1.7-2.0 mm) Innershield 350 amps
K289
(3)
5
⁄64” (2.0 mm) lnnershield 500 amps
K309
(3)
.068-5⁄64” (1.7-2.0 mm) lnnershield 250 amps
Submerged Arc K112
1
⁄16” (1.6 mm) Solid 500 amps
(1)
K466-1 connector kit required.
(2)
K489 Fast-Mate™ Adapter required.
(3)
Linconditioner™ guns are recommended for locations where smoke accumulation is a problem and conventional exhaust systems are ineffective. The available smoke removal type Innershield guns and vacuum units
can be used in these locations. Instructions are shipped with the equipment.
Page 50
ACCESSORIES
C-6 C-6
LN-9 GMA Wire Feeder
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GMA TIMER KIT (K418)
Provides the following functions:
1. Preflow Control - Provides flow of shielding gas to
the work before the arc is established. The solenoid valve is energized immediately when the gun
trigger is closed but the time delay before the wire
feeder is energized is adjustable from 0 to 1.5
seconds.
2. Postflow Control - Provides flow of shielding gas
to the work after welding is stopped. Delay of the
shut off of the solenoid valve after the gun trigger
is released is adjustable from 0.5 to 4.5 seconds.
3. Burnback Control - Provides a precise time delay
that allows the wire to be burned off at the end of
the weld. The delay is adjustable for optimum
burnback depending on wire size, processes, procedure, etc.
4. Purge - Cold Inch Switch - One momentary position energizes the gas solenoid valve but not the
wire feeder or power source. The other momentary position energizes the wire feeder but not the
power source or solenoid valve. For GMA models
only.
Install the kit according to the M15059 instructions
included with the kit.
DUAL PROCESS KIT (K317) - For Wire Feeders
Using Same Polarity
This kit permits the connection of two wire feeders to a
single power source. Both feeders must weld with the
same electrode polarity. When the trigger of the
desired wire feeder is pressed, the power source output control leads (#75, #76 and #77) will be connected
to that feeder, and the procedure as set on its controls
will be provided. The other connected wire feeder will
not be feeding wire, but its electrode circuit will be electrically hot. The kit mounts at the power source and is
connected to the power source terminal strip with the
supplied leads. Standard K196 input cable assemblies
are used to connect each wire feeder to the dual
process control circuit while the electrode lead connects to the power source.
Install the kit according to instructions included.
DUAL PROCESS KIT (K318) - With Electrode
Polarity Change Capability
Functions essentially the same as the K317 except that
the kit includes two contactors to provide different
polarities on the two wire feeders. When connected in
this manner and one trigger is pressed, the other elec-
trode will be "cold" to ground but "hot" to the other electrode. This kit can also be connected to provide the
same polarities on each feeder, but the electrode circuit
of the one not being used will be cold to work and to the
other electrode.
Install the kit according to instructions included.
NOTE: The K317 and K318 Dual Process Kits also
include mode change capability, but only when using
the DC-600 power source. This feature permits one
feeder to weld in CV Innershield mode and the other
feeder to weld in CV Submerged Arc mode, as well as
both in the same mode.
When using the Pulse Power 500 power source, the
K317 or K318 Dual Process Kits can be used only if the
procedures are close enough to use the same mode
setting. The K317 or K318 cannot switch modes on the
Pulse Power 500. An LN-9 GMAmay not be used with
an LN-7 or LN-8, although two LN-9 GMAs may be
used together.
DUAL PROCEDURE KIT (K319)
With the use of this kit, one of two different settings of
wire feed speed and voltage can be selected by a toggle switch mounted on the gun handle. The kit consists
of a control panel which mounts over the standard LN9 GMA control rheostats. This control panel has four
rheostats, a transfer relay and a polarized connector.
During installation, the standard security door is mounted over the new panel and functions in the same manner. All electrical connections are with plugs to speed
and simplify the assembly. A15-foot control cable with
a polarized connector on one end for plugging into the
new control panel is provided. On the other end of the
control cable is a small selector toggle switch and a
mounting bracket.
A K302 Extension Control Cable is required when
using the K319 with any LN-9F model.
Install the kit according to instructions included.
PULSE POWER FILTER CONVERSION KIT (K442-1)
Required for any LN-9 GMA to be used with a Pulse
Power 500, DC650 Pro, or Invertec V300 power
source. Includes a Filter Board and connection harness, easily installed in the control section and plugged
into the Voltage Board. The plug must be disconnected for use with other standard power sources.
Install the kit according to instructions included.
Page 51
ACCESSORIES
C-7 C-7
LN-9 GMA Wire Feeder
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SWIVEL PLATFORM (K178-1)
For all LN-9 GMA wire reel stand combinations. For
mounting wire feeder-wire reel stand assembly on top
of suitable Lincoln Idealarc power sources.
Recommended input cable assembly length is 10 feet
(3m) when using the K178-1.
Bolt the platform to the lift bail according to instructions
supplied with the platform (M16260).
UNDERCARRIAGE (K163)
For all LN-9 GMA wire reel stand combinations.
Includes mounting frame, front casters, 10" (254 mm)
O.D. rear wheels, and handle. Use when portability is
required. Casters mount at the front and the wheels
mount at the rear. Handle bolts to the front, which
allows the LN-9 GMA to be tilted back and wheeled like
a two-wheel truck.
CONTINUOUS FLUX FEED TANK (K320)
The K320 is available to permit the LN-9 GMA to be
used for submerged arc welding using the K112 submerged arc gun and cable. Requires a supply of compressed air at 60 to 120 psi with a flow of 1.5 cubic feet
per minute.
The kit is a complete continuous flux feeding system
including air filter, pressure regulator, gage, tank and
18 foot flux hose. It also includes a funnel for filling the
tank, plus the lift bail assembly required to mount the
tank and wire feeder to a K163 undercarriage. The
tank can also be used as a free standing assembly.
Install the tank according to instructions included with
the K320 kit.
K320 FLUX TANK LOADING
Either turn off the incoming air line or remove the quick
disconnect if one has been installed. Slightly loosen
the tank cap and let the air in the tank escape through
the holes in the side of the cap. After pressure has
been released, remove the cap from the tank. Using
the funnel provided, put 100 pounds of flux into the
tank. It is very important that only new or properly
reclaimed flux be put in the tank. Coarse particles
and/or magnetic particles will stop the flux feeding
process. New Lincoln flux is properly screened at the
factory. All reclaimed flux must be separately screened
through a vibrated screen having 0.065 - 0.075 openings and be put through a magnetic separator. The
K310 vibrated Flux Screen and a K58 Magnetic
Separator are available for this purpose. The screen in
the funnel supplied with the tank has much larger
openings, and its only purpose is to keep paper and
slag out of the tank. Screw the tank cap back on and
tighten it hand tight. Reconnect the incoming air line to
the tank.
There will always be a small amount of air and possible drops of water coming out of the end of the tube
coiled under the tank. This is an automatic disposal
system in case the plant air has water and dirt in it.
K310 FLUX SCREEN
This unit is designed to fit the top of either the standard
fill funnel of a continuous flux feed system or a K58
magnetic separator. The unit has a steel screen with
0.065 to 0.075 openings and an air vibrator attached to
the frame. The vibrator can be used with air line pressure ranging from 20 psi to 100 psi.
For ease of handling, you should connect the incoming
air line to the 1/8" pipe elbow with the aid of a fast disconnect type air coupling.
It is very important that reclaimed flux to be used in the
continuous flux feeding system be passed through the
K310 screen or its equivalent.
Page 52
K58 MAGNETIC SEPARATOR
The K58 is a permanent magnet type separator
designed to fit the top of the standard fill funnel of the
continuous flux feed system.
The purpose of the separator is to remove magnetic
materials such as mill scale and any other extraneous
magnetic materials which may have been recovered
along with the flux to be processed.
It is important to remove these magnetic particles from
the flux which is to be reused in the continuous flux
feeding system. If the magnetic material is not
removed, it will gather around the nozzle of the gun
and impede or shut off the flux flow when making relatively long welds or when welding continuously. The
magnetic particles can also cause porosity in the weld.
Fit the magnetic separator into the funnel or hopper.
Pour the flux to be reclaimed into the top pan of the
separator. The separator is designed so that the flux
flows around three permanent magnets. The magnets
remove all magnetic particles. When the magnets
become covered with their full load, they automatically
stop the flux flow. When the flux flow stops, remove the
separator from the funnel or hopper. Turn it over and
open the panel that covers the magnets. Remove the
magnetic particles by brushing or by using an air blast.
WHEN USING COMPRESSED AIR BE CAREFULTO
PROTECT YOURSELF AND OTHERS IN THE AREA
FROM FLYING PARTICLES.
NOTE: The magnetic separator is used with all
Lincoln mild steel fluxes - 700 Series, 800 Series and
900 Series. Do not use the magnetic separator with
any stainless steel, alloy, or hardsurfacing flux except
H-535. The magnetic separator removes some of the
alloying elements from these fluxes, thus changing
their characteristics.
ACCESSORIES
C-8 C-8
LN-9 GMA Wire Feeder
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WARNING
Page 53
ACCESSORIES
C-9 C-9
LN-9 GMA Wire Feeder
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TABLE C.2 – DRIVE ROLL AND GUIDE TUBE KITS
Wire Size
Kit
2-Roll 4-Roll
Solid Steel Electrode
0.023” - 0.025” (0.6 mm) KP653 - 025S KP655 - 025S
0.030” (0.8 mm) KP653 - 030S KP655 - 030S
0.035” (0.9 - 1.0 mm) KP653 - 035S KP655 - 035S
0.045” and 0.052” (1.2 - 1.4 mm) KP653 - 052S KP655 - 052S
0.062” (1.4 - 1.6 mm) KP653 - 1/16 KP655 - 1/16
0.068” (1.7 mm) ___________ KP655 - 3/32
5/64” (2.0 mm) ___________ KP655 - 3/32
3/32” (2.4 mm) ___________ KP655 - 3/32
Cored Electrode
0.035” (0.9 - 1.0 mm) KP653 - 035C KP655 - 035C
0.045 and 0.052” (1.2 - 1.4 mm) KP653 - 052C KP655 - 052C
0.062 (1.4 - 1.6 mm) KP653 - 1/16 KP655 - 1/16
0.068 (1.7 mm) KP653 - 3/32 KP655 - 3/32
5/64” (2.0 mm) KP653 - 3/32 KP655 - 3/32
3/32” (2.4 mm) KP653 - 3/32 KP655 - 3/32
Aluminum Electrode
0.035” (0.9 - 1.0 mm) KP654 - 035A KP656 - 035A
3/64” (1.2 mm) KP654 - 3/64A KP656 - 3/64A
1/16” (1.6 mm) KP654 - 1/16A KP656 - 1/16A
Page 54
NOTES
C-10 C-10
LN-9 GMA Wire Feeder
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Page 55
TABLE OF CONTENTS
- MAINTENANCE SECTION -
Section D-1 Section D-1
LN-9 GMA Wire Feeder
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Maintenance
Routine Maintenance..................................................................................................................D-2
Drive Rolls and Guide Tubes...............................................................................................D-2
Wire Reel Mounting - 50 and 60 lb. Coils............................................................................D-2
Wire Reel Mounting Readi-Reels and Spools......................................................................D-2
Periodic Maintenance .................................................................................................................D-2
Control Box...........................................................................................................................D-2
Wire Drive Motor and Gear Box...........................................................................................D-2
Gun and Cable Maintenance......................................................................................................D-3
Proper Speed Sensor Module Mounting..............................................................................D-3
Gun Cable Connector Requirements...................................................................................D-4
Page 56
SAFETY PRECAUTIONS
ELECTRIC SHOCK can kill.
• Only qualified personnel should
perform this maintenance.
• Turn the input supply power
OFF at the disconnect switch or
fuse box before working on this
equipment.
• Do not touch electrically hot parts.
ROUTINE MAINTENANCE
DRIVE ROLLS AND GUIDE TUBES
After feeding any coil of wire, inspect the drive roll section. Clean it as necessary. Do not use a solvent for
cleaning the idle rolls(s) because it may wash the lubricant out of the bearing. The drive roll(s) and guide
tubes are stamped with the wire sizes they will feed. If
you use a wire size other than that stamped on the
rolls, the roll(s) and guide tubes must be changed.
The drive rolls for 0.035 and 0.052 cored electrode and
1/16 through 7/64 electrode have a double set of teeth
so they can be reversed for additional life. Drive rolls
for 0.023 through 0.052 solid electrodes and aluminum
sizes have no teeth, but use two grooves so they also
can be reversed for additional life.
See the
Operation
Section for drive roll installation
instructions.
See
Table C.2
in the
Accessories
section for drive roll
and guide tube kits.
WIRE REEL MOUNTING - 50 AND 60 LB.
COILS WITH 1” SPINDLE
To prolong the life of the reel shaft, periodically coat it
with a thin layer of grease. No maintenance of the twoposition adjustable brake is needed. If the brake shoe
wears through to metal, replace the brake assembly.
WIRE REEL MOUNTING - READI-REELS
AND 10 THROUGH 44 LB. SPOOLS AND
50 AND 60 LB. COILS WITH K1504-1
ADAPTER
No routine maintenance required. Do not lubricate the
2" spindle.
PERIODIC MAINTENANCE
CONTROL BOX
Every six months open and inspect the control section.
The accumulated dirt should be gently blown off all of
the electrical components. Be sure the air that is being
used is dry. Check the contacts of the large plug-in
relay.
A spatter resistant shield protects the digital meter.
This shield must always be installed. If it breaks or
becomes damaged, replace it by removing the two
screws securing its frame, installing a new shield, and
reattaching the frame.
WIRE DRIVE MOTOR AND GEAR BOX
Every year examine the gearbox. Paint the gear teeth
with molydisulfide-filled grease (Lincoln specification
E2322). Do not use a graphite grease.
Check the motor brushes. Replace if they are worn
down to 1/4" or less. When ordering feed motor brushes, give all information from the motor nameplate.
MAINTENANCE
D-2 D-2
LN-9 GMA Wire Feeder
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WARNING
Page 57
GUN AND CABLE MAINTENANCE
For instructions on periodic maintenance for the welding gun and cables, refer to the manual for your specific model of welding gun.
PROPER SPEED SENSOR MODULE
MOUNTING
The LN-9 GMA Speed Sensor Module is a three lead
Hall-Effect switch device encased in an externally
threaded housing. It is screwed into a mounting plate
on the motor side of the wire drive gearbox. See
Figure D.1.
Proper positioning of this module is critical to operation
of the LN-9 GMAwire feed speed control. If the device
is not screwed in far enough, the LN-9 GMA motor
speed could be unstable or run at full speed with no
control. If screwed in too far it will rub a moving part
inside the gearbox.
The module is properly mounted to the gearbox as
shipped from the factory. If the device is ever removed
or replaced, proper mounting technique is as follows:
1. Be sure all power to the LN-9 GMAis shut off at the
power source.
2. Check that the module mounting plate is screwed
securely to the side of the gearbox and seated
flush against the top surface after being tightened.
3. Gently screw the module into the mounting plate
until it just touches and stops against the rotating
part inside the gearbox.
4. Back the module out 1/2 turn, then snug the module locknut without rotating the module position.
MAINTENANCE
D-3 D-3
LN-9 GMA Wire Feeder
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FIGURE D.1 – SPEED SENSOR MODULE LOCATION
Page 58
The following Figures D.2 and D.3 should serve as a
guide to determine if a particular gun or switch can be
connected to the LN-9 GMA and LN-9F GMA.
“A” Diameter Hole
to be Concentric to
Wire Size .749/.747 (19.0/18.9)
in. (mm) Diameter Within .008 (.20) F.I.M.
0.68-5/64 (1.7-2.0) .125 [1/8” (3.2 mm) Drill]
1/16-0.062 (1.6) .078 [5/64” (2.0 mm) Drill]
.045 & .052 (1.1 & 1.3) .062 [1/16” (1.6 mm) Drill]
.023-.035 (0.6-0.9) .055 [(1.4 mm) #54 Drill]
All dimensions in inches and (millimeters).
1/2 Amp AC 24 Volts — Inductive
1/2 Amp DC 24 Volts — Inductive
MAINTENANCE
D-4 D-4
LN-9 GMA Wire Feeder
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FIGURE D.2 – LN-9 GMA CONNECTORS
GUN CABLE CONNECTOR REQUIREMENTS TO PERMIT PROPER CONNECTION TO LINCOLN LN-9 GMA AND LN-9F
GMA WIRE FEEDER
LN-9 CONNECTOR FOR 1/16-5/64” (1.6-2.0 MM) WIRE)
LN-9 CABLE CONNECTOR FOR .023-.052” (0.6-1.3 mm)
WIRE (FOR ALL OTHER DIMENSIONS, SEE DIAGRAM
ABOVE).
NOTE: Connector part with .7459/.747 (19.0/18.9)
diameter should be made from brass if it is to be part
of the welding current carrying circuit.
FIGURE D.2 – SWITCH REQUIREMENTS
Page 59
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Section E-1 Section E-1
LN-9 GMA Wire Feeder
Theory of Operation .............................................................................................................Section E
General Description...............................................................................................................E-2
Power Input Circuits...............................................................................................................E-2
Trigger and Shutdown Circuit................................................................................................E-3
Arc Voltage, Wire Speed Control and Metering.....................................................................E-4
Printed Circuit Board Functions .............................................................................................E-5
TABLE OF CONTENTS
-THEORY OF OPERATION SECTION-
INPUT
CONNECTOR
TO
VOLTAGE
BOARD
TO
CONTROL
BOARD
METER
BOARD
VOLTS
SPEED
SWITCH
T1
CIRCUIT
BREAKER
R1
TRIGGER
CONNECTOR
TRIGGER
BOARD
F
U
S
E
T2
C
O
N
T
R
O
L
B
O
A
R
D
VOLTAGE
BOARD
P
O
W
E
R
B
O
A
R
D
GROUND
LEAD
PROTECTOR
WIRE
FEED
MOTOR
WIRE
SPEED
CONTROL
VOLTAGE
CONTROL
POLARITY
SWITCH
VOLTAGE SENSING
VOLTAGE CONTROL
POWER SOURCE OUTPUT TRIGGER (#2 )
S
H
U
T
D
O
W
N
+ 15VDC
+ 15VDC
WIRE SPEED CONTROL
GEAR
BOX
TRIGGER SIGNAL
TRIGGER SIGNAL
R
E
F
E
R
E
N
C
E
V
O
L
T
A
G
E
WORK
ELECTRODE VOLTAGE SENSING
24VAC
28VAC
10VAC
HALL EFFECT
DEVICE
GAS
SOLENOID
FIGURE E.1 – LN-9 GMA BLOCK LOGIC DIAGRAM
Page 60
POWER INPUT CIRCUITS
The 1 15VAC is applied (usually from the welding power
source) via the input connector and through the circuit
breaker and R1 resistor to the power board, the T2 trigger transformer, and the T1 transformer.
The 24VAC developed at the T2 trigger transformer is
applied to the trigger board. There it is rectified and
regulated to 20VDC and used to operate the wire feeder trigger circuitry.
The 28VAC produced by the T1 transformer secondary
is applied to the power board. There it is rectified and
regulated to 15VDC. This 15VDC powers the electronics on the power, control, and voltage boards. The
10VAC secondary voltage is rectified, regulated, and
utilized by the meter board.
THEORY OF OPERATION
E-2 E-2
LN-9 GMA Wire Feeder
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NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
GENERAL DESCRIPTION
The LN-9 GMA is a semiautomatic wire feeder that allows
the user to preset the arc voltage and wire feed speed.
The wire feed speed is internally monitored and
regulated to the preset condition. When the LN-9 GMA is
coupled to an appropriate Lincoln constant voltage
power source, the actual arc voltage is also regulated to
match the preset voltage. The LN-9 GMA models also
incorporate a factory installed gas solenoid valve, high
speed wire drive, adjustable run-in and acceleration
speeds, and a two-step/four-step trigger interlock system.
FIGURE E.2 – POWER INPUT CIRCUITS
INPUT
CONNECTOR
TO
VOLTAGE
BOARD
TO
CONTROL
BOARD
METER
BOARD
VOLTS
SPEED
SWITCH
T1
CIRCUIT
BREAKER
R1
TRIGGER
CONNECTOR
TRIGGER
BOARD
F
U
S
E
T2
C
O
N
T
R
O
L
B
O
A
R
D
VOLTAGE
BOARD
P
O
W
E
R
B
O
A
R
D
GROUND
LEAD
PROTECTOR
WIRE
FEED
MOTOR
WIRE
SPEED
CONTROL
VOLTAGE
CONTROL
POLARITY
SWITCH
VOLTAGE SENSING
VOLTAGE CONTROL
POWER SOURCE OUTPUT TRIGGER (#2 )
S
H
U
T
D
O
W
N
+ 15VDC
+ 15VDC
WIRE SPEED CONTROL
GEAR
BOX
TRIGGER SIGNAL
TRIGGER SIGNAL
R
E
F
E
R
E
N
C
E
V
O
L
T
A
G
E
WORK
ELECTRODE VOLTAGE SENSING
24VAC
28VAC
10VAC
HALL EFFECT
DEVICE
GAS
SOLENOID
Page 61
TRIGGER AND SHUTDOWN
CIRCUIT
When the gun trigger switch is activated (closed), the
trigger board completes the trigger signal path. This
energizes the CR1 relay located on the power board.
The CR1 relay activates the wire drive motor and the
#2 and #4 circuit, which then activates the Lincoln
welding power source. The CR1 relay is also used to
energize the gas solenoid.
The normally closed relay located on the voltage
board is in series with the trigger signal. If an out-ofvoltage-range signal or a ground fault condition
should occur, the CR501 (on voltage board) relay contacts would "open," and the trigger signal path would
be interrupted. This would cause the wire feeder to
"shut down" until the gun trigger is released or the
ground fault protector is reset.
THEORY OF OPERATION
E-3 E-3
LN-9 GMA Wire Feeder
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NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
FIGURE E.3 – TRIGGER AND SHUTDOWN CIRCUIT
VOLTAGE CONTROL
VOLTAGE SENSING
WORK
HALL EFFECT
DEVICE
B
O
A
R
D
ELECTRODE VOLTAGE SENSING
WIRE SPEED CONTROL
+ 15VDC
GAS
SOLENOID
TRIGGER SIGNAL
+ 15VDC
POLARITY
WIRE
SPEED
CONTROL
C
O
B
O
N
A
T
R
R
D
O
R
E
F
E
R
E
N
C
E
V
O
L
T
A
G
E
VOLTAGE
BOARD
L
S
H
U
T
D
O
W
N
SWITCH
VOLTAGE
CONTROL
TO
VOLTAGE
BOARD
INPUT
CONNECTOR
CONTROL
BOARD
METER
BOARD
VOLTS
SPEED
SWITCH
TO
10VAC
POWER SOURCE OUTPUT TRIGGER (#2 )
CIRCUIT
BREAKER
T1
TRIGGER
CONNECTOR
R1
28VAC
TRIGGER
BOARD
24VAC
GEAR
BOX
WIRE
FEED
MOTOR
T2
F
U
S
E
P
O
W
E
R
TRIGGER SIGNAL
GROUND
LEAD
PROTECTOR
Page 62
ARC VOLTAGE, WIRE SPEED
CONTROL AND METERING
The arc voltage, which is sensed at the work piece and
motor gear box, is connected through a polarity switch
to the voltage board. This actual arc voltage is compared to the reference preset voltage that is set by the
voltage control. The voltage board determines what
correction signal needs to be sent to the Lincoln welding power supply. This voltage control signal is coupled to the power supply through the input connector.
The Lincoln power supply then adjusts the welding arc
voltage to meet the demands of the preset reference
voltage.
The hall effect device sends motor speed information
to the control board. This feedback voltage is compared to the reference command preset by the wire
speed control. The control board determines what correction is needed and sends the appropriate signal to
the power board. The power board then adjusts the
motor armature voltage to comply with the command
from the control board.
A three-digit meter is provided to read both arc voltage
and wire feed speed. Either the preset or the actual
welding parameters can be displayed.
THEORY OF OPERATION
E-4 E-4
LN-9 GMA Wire Feeder
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NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
FIGURE E.4 – ARC VOLTAGE, WIRE SPEED CONTROL AND METERING
VOLTAGE CONTROL
VOLTAGE SENSING
WORK
HALL EFFECT
DEVICE
B
O
A
R
D
TRIGGER SIGNAL
ELECTRODE VOLTAGE SENSING
WIRE SPEED CONTROL
+ 15VDC
GAS
SOLENOID
TRIGGER SIGNAL
+ 15VDC
POLARITY
WIRE
SPEED
CONTROL
C
O
B
O
N
A
T
R
R
D
O
R
E
F
E
R
E
N
C
E
L
V
O
L
T
A
G
E
VOLTAGE
BOARD
S
H
U
T
D
O
W
N
SWITCH
VOLTAGE
CONTROL
TO
VOLTAGE
BOARD
INPUT
CONNECTOR
TO
CONTROL
BOARD
METER
BOARD
VOLTS
SPEED
SWITCH
10VAC
POWER SOURCE OUTPUT TRIGGER (#2 )
CIRCUIT
BREAKER
T1
TRIGGER
CONNECTOR
R1
28VAC
TRIGGER
BOARD
24VAC
GEAR
BOX
WIRE
FEED
MOTOR
T2
F
U
S
E
P
O
W
E
R
GROUND
LEAD
PROTECTOR
Page 63
PRINTED CIRCUIT BOARD
FUNCTIONS
POWER BOARD
The input power (115VAC) is applied to the power
board, and from that the power board develops the
variable DC armature voltage for the permanent magnet wire drive motor. The SCR circuitry, used to control the motor armature voltage, is also contained on
the power board.
The relay used to activate motor armature voltage, the
gas solenoid, and power source output (#2 and #4) is
housed on the power board.
The shut down, start response and trigger interlock circuitry, in addition to the rectified and regulated power
supplies used for the LN-9 GMA control circuitry, are
included in the power board design.
CONTROL BOARD
The control board provides a reference voltage to the
wire speed control and voltage control potentiometers,
allowing SET (pre-set) signals to be produced.
The control board also powers and processes the feedback signals from the hall effect device. It compares
the actual speed information to the SET speed command signal and develops firing pulses that drive the
motor armature SCR circuitry, located on the power
board.
Acceleration and run-in rates for wire feed speed are
controlled by the control board as well as the SET speed
and actual speed signals for the digital meter circuitry
.
VOLTAGE BOARD
The voltage board compares the SET voltage values to
the actual voltage values and makes any necessary
correction by sending the appropriate signal to the
Lincoln CV power source. If for any reason the arc
voltage cannot be controlled to the SET voltage, the
voltage board interrupts the LN-9 GMA trigger path,
and the unit shuts down. The response (Fast or Slow)
to changes in arc voltage is also controlled by the voltage board, as well as the SET and actual arc voltage
signals for the digital meter circuitry.
TRIGGER BOARD
The trigger transformer supplies 24VAC to the trigger
board where it is rectified and regulated to 20VDC.
This DC voltage is used in the gun trigger circuit to initiate the welding operation.
HALL EFFECT DEVICE
A square wave frequency signal, proportional to motor
speed, is generated by the hall effect device and sent
to the control board.
METER BOARD
The meter board contains signal scaling and power
supply circuitry for the digital meter.
THEORY OF OPERATION
E-5 E-5
LN-9 GMA Wire Feeder
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Page 64
NOTES
E-6 E-6
LN-9 GMA Wire Feeder
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Page 65
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Section F-1 Section F-1
LN-9 GMA Wire Feeder
Troubleshooting & Repair Section................................................................................Section F
How to Use Troubleshooting Guide.......................................................................................F-2
PC Board Troubleshooting Procedures.................................................................................F-3
Troubleshooting Guide ................................................................................................F-4 - F-23
Test Procedures
T1 Transformer Test ......................................................................................................F-24
T2 Transformer Test ......................................................................................................F-27
Wire Drive Motor Test....................................................................................................F-31
Hall Effect Test and Alignment.......................................................................................F-34
Voltmeter Accuracy Test................................................................................................F-38
Meter Circuit Accuracy Test...........................................................................................F-41
Wire Speed Accuracy Test ............................................................................................F-46
Out of Voltage Range Shut Down Test .........................................................................F-48
General Power Supply Tests.........................................................................................F-51
Replacement Procedures
Digital Meter and Meter PC Board Removal and Replacement ...................................F-54
Reed Switch (CR2) Removal and Replacement...........................................................F-57
T1 Transformer Removal and Replacement.................................................................F-59
Drive Motor Removal and Replacement.......................................................................F-64
Retest After Repair...............................................................................................................F-69
TABLE OF CONTENTS
TROUBLESHOOTING & REPAIR SECTION
NOTE
This Troubleshooting section is specific to the
LN-9 GMA. However, much of this information
may apply to the LN-9 F GMA model with slight
adaptation. Refer to LN-9F GMAWiring Diagram.
Page 66
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HOW TO USE TROUBLESHOOTING GUIDE
Service and repair should be performed by only Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and machine
operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please
observe all safety notes and precautions detailed throughout this manual.
TROUBLESHOOTING & REPAIR
F-2 F-2
LN-9 GMA Wire Feeder
CAUTION
This Troubleshooting Guide is provided to help
you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below.
Step 1. LOCATE PROBLEM (SYMPTOM). Look
under the column labeled “PROBLEM (SYMPTOMS). This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the
machine is exhibiting. Symptoms are grouped
into main categories: Function Problems, Feeding
Problems, Welding Problems, Meter Problems,
and Starting Problems.
Step 2. PERFORM EXTERNAL TESTS. The
second column, labeled “POSSIBLE AREAS OF
MISADJUSTMENT(S)”, lists the obvious external
possibilities that may contribute to the machine
symptom. Perform these tests/checks in the
order listed. In general, these tests can be conducted without removing the case wrap-around
cover.
Step 3. PERFORM COMPONENT TESTS. The
last column, labeled “Recommended Course of
Action” lists the most likely components that may
have failed in your machine. It also specifies the
appropriate test procedure to verify that the subject component is either good or bad. If there are
a number of possible components, check the
components in the order listed to eliminate one
possibility at a time until you locate the cause of
your problem.
All of the referenced test procedures referred to in
the Troubleshooting Guide are described in detail
at the end of this chapter. Refer to the
Troubleshooting and Repair Table of Contents to
locate each specific Test Procedure. All of the
referred to test points, components, terminal
strips, etc., can be found on the referenced electrical wiring diagrams and schematics. Refer to
the Electrical Diagrams Section Table of Contents
to locate the appropriate diagram.
WARNING
If for any reason you do not understand the test procedures or are unable to perform the test/repairs
safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before
you proceed. Call 216-383-2531 or 1-800-833-9353.
Page 67
ELECTRIC SHOCK can kill.
Have an electrician install and service
this equipment. Turn the machine OFF
before working on equipment. Do not
touch electrically hot parts.
Sometimes machine failures appear to be due to PC
board failures. These problems can sometimes be
traced to poor electrical connections. To avoid problems when troubleshooting and replacing PC boards,
please use the following procedure:
1. Determine to the best of your technical ability that
the PC board is the most likely component causing
the failure symptom.
2. Check for loose connections at the PC board to
assure that the PC board is properly connected.
3. If the problem persists, replace the suspect PC
board using standard practices to avoid static electrical damage and electrical shock. Read the warning inside the static resistant bag and perform the
following procedures:
PC Board can be damaged by
static electricity.
• Remove your body’s static charge
before opening the static-shielding
bag. Wear an anti-static wrist
strap. For safety, use a 1 Meg
ohm resistive cord connected to a
grounded part of the equipment
frame.
• If you don’t have a wrist strap,
touch an unpainted, grounded,
part of the equipment frame. Keep
touching the frame to prevent static build-up. Be sure not to touch
any electrically live parts at the
same time.
• Tools which come in contact with the PC Board must
be either conductive, anti-static or static-dissipative.
• Remove the PC Board from the static-shielding bag
and place it directly into the equipment. Don’t set the
PC Board on or near paper, plastic or cloth which
could have a static charge. If the PC Board can’t be
installed immediately , put it back in the static-shielding
bag.
• If the PC Board uses protective shorting jumpers,
don’t remove them until installation is complete.
• If you return a PC Board to The Lincoln Electric
Company for credit, it must be in the static-shielding
bag. This will prevent further damage and allow proper failure analysis.
4. Test the machine to determine if the failure symp-
tom has been corrected by the replacement PC
board.
NOTE: Allow the machine to heat up so that all electri-
cal components can reach their operating temperature.
5. Remove the replacement PC board and substitute
it with the original PC board to recreate the original
problem.
a. If the original problem does not reappear
by substituting the original board, then the
PC board was not the problem. Continue
to look for bad connections in the control
wiring harness, junction blocks, and terminal strips.
b. If the original problem is recreated by the
substitution of the original board, then the
PC board was the problem. Reinstall the
replacement PC board and test the
machine.
6. Always indicate that this procedure was followed
when warranty reports are to be submitted.
NOTE: Following this procedure and writing on the
warranty report, “INSTALLED AND
SWITCHED PC BOARDS TO VERIFY PROBLEM,” will help avoid denial of legitimate PC
board warranty claims.
TROUBLESHOOTING & REPAIR
F-3 F-3
LN-9 GMA Wire Feeder
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Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
PC BOARD TROUBLESHOOTING PROCEDURES
WARNING
ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
Workstations
Reusable
Container
Do Not Destroy
Page 68
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TROUBLESHOOTING & REPAIR
F-4 F-4
LN-9 GMA Wire Feeder
Observe Safety Guidelines TROUBLESHOOTING GUIDE
detailed in the beginning of this manual.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
No wire feed when gun trigger is
activated. The digital meter does
NOT light. The drive rolls do not
turn.
1. Make sure 115VAC is being
applied to the LN-9 GMA at the
input connector. Pin "C" is lead
#31 and pin "D" is lead #32.
2. Check the 3 amp circuit breaker .
Reset if tripped.
3. The F101 4/10 amp slow blow
fuse, located on the power PC
board, may be blown.
1. Check for loose or faulty lead
connections between the input
connector, the T1 transformer,
and the power PC board.
2. The T1 transformer may be
faulty. Perform the
T1 Trans-
former Test.
Page 69
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TROUBLESHOOTING & REPAIR
F-5 F-5
LN-9 GMA Wire Feeder
TROUBLESHOOTING GUIDE Observe Safety Guidelines
detailed in the beginning of this manual.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216383-2531 or 1-800-833-9353.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
No wire feed when gun trigger is
activated. The drive rolls do not
turn. The digital meter does light
but reads only SET voltage and
wire speed values.
1. The Ground Lead Protector
may have tripped. Reset and
clear possible fault between
electrode circuit and feeder
frame.
2. The gun trigger may be faulty.
1. The 1CR relay on the power PC
board may be faulty. Check or
replace.
2. Check resistor R1. Normal
resistance is 2 ohms.
3. Perform the
Trigger
Transformer T2 Test.
4. Perform the
Wire Drive Motor
Test.
5. The T rigger Board may be faulty.
6. If the wire drive motor is OK, the
power PC board or the control
board may be faulty.
Page 70
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TROUBLESHOOTING & REPAIR
F-6 F-6
LN-9 GMA Wire Feeder
Observe Safety Guidelines TROUBLESHOOTING GUIDE
detailed in the beginning of this manual.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
The wire feed “coasts” when the gun trigger is released.
1. Make sure the gun trigger is not
“sticking.”
1. The relay 1CR may be faulty.
Replace.
The gas solenoid does not activate
when the gun trigger is closed. The
wire feeds and arc voltage is present.
1. If a K418 GMA Timer Kit or a
K419 Burnback Timer Kit is
installed, disconnect it and
replace it with the jumper plug.
If the problem is resolved, the
K418 or K419 is faulty.
1. With the gun trigger closed,
check for 115VAC at the power
PC board terminals #7A to
#32A.
a. If the 115VAC is present,
the solenoid may be faulty.
Replace.
b. If the 115VAC is NOT pre-
sent at terminals #7 and
#32, the relay CR1 on the
power PC board may be
faulty. Replace.
The gas solenoid stays open after the gun trigger switch is released.
1. The gas solenoid may be stuck
in the open position.
1. With the gun trigger NOT
closed, check for 115VAC at the
power PC board terminals #7 to
#32A.
a. If the 115VAC is present,
the relay CR1 may be
defective.
b. If the 115VAC is NOT pre-
sent, the gas solenoid may
be defective.
Page 71
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TROUBLESHOOTING & REPAIR
F-7 F-7
LN-9 GMA Wire Feeder
TROUBLESHOOTING GUIDE Observe Safety Guidelines
detailed in the beginning of this manual.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216383-2531 or 1-800-833-9353.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
The wire feeds when the gun trigger is activated, but there is no arc
voltage.
1. Make sure the interlock switch
is in a "Wire Hot" position.
2. Check the welding cables for
loose or faulty connections.
3. Put a jumper wire from #2 to #4
on the power source terminal
strip. (Machines with 14 pin
amphenols: pin C to pin D.) If
the arc voltage is not present at
the output terminals, the power
source is faulty. If the arc voltage IS present, the problem is
in the wire feeder or control
cable.
4. Check the continuity of leads #2
and #4 through the control
cable. Replace if "open."
1. The 1CR relay, located on the
power PC board, may be faulty.
Check or replace.
2. If a burnback kit is installed,
remove and install the jumper
plug. If the problem is solved,
the burnback kit is faulty.
3. Check the #2 and #4 leads in
the LN-9 GMA wiring harness
for loose or faulty connections.
See the Wiring Diagram.
Page 72
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TROUBLESHOOTING & REPAIR
F-8 F-8
LN-9 GMA Wire Feeder
Observe Safety Guidelines TROUBLESHOOTING GUIDE
detailed in the beginning of this manual.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
The SET speed is adjustable and
steady. The actual speed is uncontrollable. The meter displays the
actual speed correctly or reads
"EEE."
1. Contact your local Lincoln
Authorized Field Service
Facility.
1. While the motor is running,
carefully unplug the 15 pin
molex plug from the control PC
board.
If the motor continues to run,
the power PC board may be
faulty. Replace.
If the motor stops, the control
PC board may be faulty.
Replace.
2. Perform the
Wire Drive Motor
Test.
The SET speed is adjustable and steady. The actual speed reading is incorrect and/or erratic.
1. Check for loose or faulty connections on leads #510, #525,
and #555 between the hall
effect module and the control
PC board.
1.
Perform the
Hall Effect Module
Alignment Procedure
.
2. Perform the
Hall Effect Feed-
back Test.
3. If the
Hall Effect Feedback
Test
is OK, the control PC
board may be faulty. Replace.
Page 73
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TROUBLESHOOTING & REPAIR
F-9 F-9
LN-9 GMA Wire Feeder
TROUBLESHOOTING GUIDE Observe Safety Guidelines
detailed in the beginning of this manual.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
The SET speed is erratic or not
adjustable over entire range of control. The actual speed is also erratic like the SET speed.
1. Check for loose or faulty connections on leads #631, #632,
and #633 between the speed
control potentiometer (R2) and
the control PC board.
1. Remove power to the LN-9
GMA and disconnect the plug to
the control PC board. Check
the resistance of the speed control potentiometer (R2). When
measured from the wiper (lead
#632) to lead #633, the resistance should vary smoothly
from 0 to 10,000 ohms when the
shaft is rotated. See the Wiring
Diagram.
2. The control PC board may be
faulty. Replace.
The wire continues to feed with the
gun trigger open, and the wire is
electrically "hot." The interlock
switch is in the "OFF" position.
1. Disconnect the gun trigger cable.
If the problem is resolved, the
gun trigger or cable is faulty.
Repair or replace.
1. Disconnect lead #530 from the
trigger PC board. See the
Wiring Diagram. If the problem
is resolved, the trigger board is
faulty. Replace.
2. Relay 1CR may be stuck
closed. Check or replace.
3. The power PC board may be
faulty. Replace.
Page 74
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TROUBLESHOOTING & REPAIR
F-10 F-10
LN-9 GMA Wire Feeder
Observe Safety Guidelines TROUBLESHOOTING GUIDE
detailed in the beginning of this manual.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
TRIGGER INTERLOCK FUNCTION PROBLEMS
The wire feeds when the interlock switch is in the "ON" position. No welding or gun trigger activation.
1. Check to see if the reed switch
2CR is stuck closed.
1. Check the 2CR reed switch for
sticking and associated leads
(#529 and #628) for shorts.
2. The power PC board may be
faulty. Replace.
With the interlock switch in the "ON" position, the wire feed stops when the gun trigger is released.
1. Check leads #529 and #628 for
loose or faulty connections
between the 2CR reed switch
and the power PC board.
1. The 2CR reed switch may be
faulty. Check to see if it closes
when welding.
2. Check the continuity (zero
ohms) of leads #529 and #628
from the 2CR reed switch to the
power PC board. Also check
continuity of leads #530 and
#522 from the power PC board
to the interlock switch. See the
Wiring Diagram.
3. Check the interlock switch for
proper operation.
4. The power PC board may be
faulty. Replace.
Page 75
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TROUBLESHOOTING & REPAIR
F-11 F-11
LN-9 GMA Wire Feeder
TROUBLESHOOTING GUIDE Observe Safety Guidelines
detailed in the beginning of this manual.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
The SET voltage is erratic or not
adjustable over the entire range of
control. The actual voltage is also
erratic like the SET voltage.
1. Check for loose or faulty connections on leads #634, #635,
and #636 between the voltage
control potentiometer (R3) and
the voltage PC board.
1. Remove power to the LN-9
GMA and disconnect Plug J9
from the voltage PC board.
Check the resistance of the voltage control potentiometer (R3).
When measured from the wiper
(lead #635) to lead #634, the
resistance should vary smoothly
from 0 to 10,000 ohms when the
shaft is rotated.
2. The voltage PC board may be
faulty. Replace.
The field fuse (F101), located on the power PC board, repeatedly fails.
1. Make sure the replacement fuse
is a 4/10 amp slow blow type
fuse.
1. Perform the
T1 Transformer
Test.
2. Disconnect the meter PC board.
If the problem is resolved, the
meter PC board may be faulty.
3. The power PC board may be
faulty. Replace.
Page 76
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F-12 F-12
LN-9 GMA Wire Feeder
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE Observe Safety Guidelines
detailed in the beginning of this manual.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
Circuit breaker (3 amp) repeatedly
trips when the gun trigger is activated.
1. Check or replace gun trigger
and leads. Make sure the trigger leads are not shorted to the
electrode or work cables.
1. Disconnect lead #500 from the
trigger PC board. If the breaker
still trips when the gun trigger is
activated, the trigger PC board
may be faulty. Replace
2. Disconnect any accessory that
may be connected to terminals
#7 and #32A. See the Wiring
Diagram. If the problem is
resolved, the accessory may be
faulty. Replace.
3. Perform the
Wire Drive Motor
Test.
4. The power PC board may be
faulty. Replace.
Circuit breaker (3 amp) trips when power is applied to the LN-9 GMA. Gun trigger is NOT activated.
1. Disconnect any kits that may be
incorporated in the LN-9 GMA
(K418, K419, etc.). Be sure to
install any necessary jumper
plugs. If the problem is resolved, the fault may be in the
disconnected kit.
1. Disconnect lead #620 from the
trigger PC board. See the
Wiring Diagram. If the problem
is resolved, the trigger PC
board may be faulty. Replace.
2. Perform the
T2 Transformer
Test.
3. Check the harness leads #32A,
#31, and #531 for shorts or
grounds. See the Wiring
Diagram.
4. The power PC board may be
faulty. Replace.
Page 77
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TROUBLESHOOTING & REPAIR
F-13 F-13
LN-9 GMA Wire Feeder
TROUBLESHOOTING GUIDE Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
The 1/8 amp fuse on the voltage PC board repeatedly fails.
1. Check to make sure the PC
boards are NOT grounded to
the case of the LN-9 GMA.
This can happen due to metallic wire shavings build-up.
1. Remove input power to the LN9 GMA. Replace the 1/8 amp
fuse and switch the LN-9 GMA
polarity switch to the "NEG"
position.
Make a resistance check from
the following leads to the LN-9
GMA case grounding screw:
Leads # 500, 510, 525, 522,
526, 530, and 628.
The resistances should be
above 1000 ohms. If any test
is below 1000 ohms, that circuit
has low resistance to case
ground. Isolate the faulty leads
or PC board. See the Wiring
Diagram and Schematic.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.
Page 78
TROUBLESHOOTING & REPAIR
F-14 F-14
LN-9 GMA Wire Feeder
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Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
TROUBLESHOOTING GUIDE Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
The LN-9 GMA shuts down while welding. Upon retriggering the gun, the unit will weld again for a period of time.
1. Make sure the power source
and wire feeder polarity switches are set correctly for the
process being used.
2. Make certain the voltage control
switch on the Lincoln CV power
source is set in the "Remote"
position.
3. Make sure the #21 lead in the
control cable has continuity to
the work piece.
4. Check the 1/8 amp fuse on the
LN-9 GMA voltage PC board.
Replace if faulty.
5. Be sure the welding power
source is compatible with the
LN-9 GMA.
1. Perform the
Out of Voltage
Range Shutdown Test.
2. The control cable may be faulty.
Check or replace.
3. The voltage PC board may be
faulty. Replace.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.
Page 79
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TROUBLESHOOTING & REPAIR
F-15 F-15
LN-9 GMA Wire Feeder
TROUBLESHOOTING GUIDE Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FEEDING PROBLEMS
When the gun trigger is activated the drive rolls turn, but the wire will not feed or wire feeding is rough.
1. Check or replace the gun cable.
It may be kinked, clogged, or
twisted.
2. Make certain the drive rolls and
guide tubes are correct for the
wire being used.
3. Check or replace the gun contact tip.
4. The electrode wire may be rusty
or dirty. Replace if necessary.
1. If conditions are extremely dirty,
install a wiper on the wire before
it enters the guide tube. Use a
piece of cloth saturated with
"Pyroil B."
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.
Page 80
TROUBLESHOOTING & REPAIR
F-16 F-16
LN-9 GMA Wire Feeder
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Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
TROUBLESHOOTING GUIDE Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
WELDING PROBLEMS
The welding arc is variable or "hunting."
1. Make sure the welding parameters are correct for the welding
procedure being used.
2. Check the welding cables for
loose or faulty connections.
3. The gun cable may be faulty.
Check or replace.
4. The gun contact tip may be
worn. Check or replace.
6. The welding power supply may
be faulty. Check or replace.
1. Put the power source in
"Machine Control" for voltage,
and check whether welding performance improves. If the problem is resolved, check or
replace the control cable. Or,
the LN-9 GMAvoltage PC board
may be faulty.
2. Perform the
Wire Drive Motor
Test.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.
Page 81
TROUBLESHOOTING & REPAIR
F-17 F-17
LN-9 GMA Wire Feeder
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TROUBLESHOOTING GUIDE Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
WELDING PROBLEMS
Poor arc striking with sticking or "blast offs." The weld bead may also be ropey and display weld porosity.
1. Make sure the welding parameters and techniques are correct
for the welding procedure being
used.
2. Check the welding cables for
loose or faulty connections.
3. The gun cable may be faulty.
Check or replace.
4. The gun contact tip may be
worn. Check or replace.
5. The welding power source may
be faulty. Check or replace.
1. Put the power source in
"Machine Control" and check
whether welding performance
improves. If the problem is
resolved, check or replace the
control cable. Or, the LN-9
GMA voltage PC board may be
faulty.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.
Page 82
TROUBLESHOOTING & REPAIR
F-18 F-18
LN-9 GMA Wire Feeder
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TROUBLESHOOTING GUIDE Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
METER FUNCTION PROBLEMS
The arc is unstable or oscillating. 1. Check the welding cables for
loose or faulty connections.
2. Make sure the electrode and
gas (if used) are correct for the
process being used.
3. Put the Lincoln power source in
the “Machine Control” mode.
Jumper the “BYPASS” pins on
the LN-9 GMA voltage PC
board. Adjust the weld voltage
from the power source for the
process being used. If the problem is NOT resolved, the power
source may be faulty.
1. The LN-9 GMA voltage PC
board may be faulty. Replace.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.
Page 83
INSTALLATION
F-19 F-19
LN-9 GMA Wire Feeder
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TROUBLESHOOTING GUIDE Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
The SET and actual speed meter readings match within a few IPM, but both are in error.
1. Contact your local Lincoln
Authorized Field Service
Facility.
1. Perform the
Hall Effect
Alignment Procedure.
2. Perform the
Meter Circuit
Accuracy Test.
3. The control PC board may be
faulty. Replace.
SET speed and actual speed meter readings do NOT match within a few IPM. One or both readings may be erratic.
1. Contact your local Lincoln
Authorized Field Service
Facility.
1. Check the Volts-Speed meter
selector switch and the associated wiring. See the Wiring
Diagram.
2. Check the SET-ACTUAL switch
and the associated wiring. See
the Wiring Diagram.
3. Perform the
Hall Effect
Alignment Procedure.
4. Perform the
Meter Circuit
Accuracy Test.
METER FUNCTION PROBLEMS
Page 84
TROUBLESHOOTING & REPAIR
F-20 F-20
LN-9 GMA Wire Feeder
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TROUBLESHOOTING GUIDE Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
METER FUNCTION PROBLEMS
SET volts and actual volts readings
match within a few tenths of a volt
while welding. However, both readings are inaccurate.
1. Put the Lincoln power source in
the "Machine Control" mode.
Check to see if the power
source can be set for the arc
voltage required for the process.
If not, the power source may be
faulty.
2. The control cable may be faulty.
Check or replace.
1. Check the voltage sensing
leads for continuity (zero ohms).
Lead #21 should have continuity to the work piece, and #67
should have continuity to the
brass conductor block. See the
Wiring Diagram.
2. Perform the
Meter Circuit
Accuracy Test.
3. The voltage PC board may be
faulty. Replace.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.
The actual volts reading does NOT
match the SET volts reading within
a few tenths of a volt while welding.
One reading may be erratic. The
LN-9 GMA does NOT shut off.
NOTE: The Pulse Power Filter kit
may slow down the shutdown feature.
1. Make sure the shutdown
"BYPASS" pins are NOT
jumpered together on the LN-9
GMA voltage PC board.
2. Check the voltage sensing
leads for continuity (zero ohms).
Lead #21 should have continuity to the work piece, and #67
should have continuity to the
brass conductor block. See the
Wiring Diagram.
3. Put the Lincoln power source in
the "Machine Control" mode.
Check to see if the power supply can be set for the arc voltage required for the process. If
not, the power supply may be
faulty.
1. If the actual reading is the problem, check the actual volts
switch and associated leads.
2. If the SET reading is the problem, check the set volts switch
and the associated leads.
3. Check the Volts-Speed selector
switch and associated leads.
4. The voltage PC board may be
faulty. Replace.
Page 85
TROUBLESHOOTING & REPAIR
F-21 F-21
LN-9 GMA Wire Feeder
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TROUBLESHOOTING GUIDE Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
STARTING PROBLEMS
The output voltage is too low to start the weld.
1. Check the welding cables for
loose or faulty connections.
2. Put the Lincoln power source in
the "Machine Control" mode.
Jumper the "BYPASS" pins on
the LN-9 GMA voltage PC
board. Adjust the weld voltage
from the power source for the
process being used. If the correct voltage cannot be set, the
power source may be faulty.
3.
Check for correct control cable
connections to the power supply .
4. The control cable may be faulty.
Check or replace.
1. Check the voltage control
potentiometer (R3) and the
associated leads. See the
Wiring Diagram.
2. The voltage PC board may be
faulty. Replace.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.
Page 86
TROUBLESHOOTING & REPAIR
F-22 F-22
LN-9 GMA Wire Feeder
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TROUBLESHOOTING GUIDE Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
STARTING PROBLEMS
Voltage seems to be too high or the arc flares at the start of weld. Welding is good.
1.
Adjust the "start" trimmer on the
voltage PC board. It should be
only slightly higher than the weld
voltage. See
Starting Charac-
teristics
in the
Operation
section
of this manual.
2. Put the Lincoln power source in
the "Machine Control" mode.
Jumper the "BYPASS" pins on
the LN-9 GMA voltage PC
board. Adjust the weld voltage
from the power source for the
process being used. If the correct voltage cannot be set, the
power source may be faulty.
3.
Check for correct control cable
connections to the power supply .
1. The LN-9 GMA voltage PC
board may be faulty. Replace.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.
Page 87
TROUBLESHOOTING & REPAIR
F-23 F-23
LN-9 GMA Wire Feeder
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TROUBLESHOOTING GUIDE Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
STARTING PROBLEMS
The arc voltage appears to rise too
slowly or stubs or blasts at the start
of a weld. Once started the welding is good.
NOTE: Pulse Power 500 operation
with a filter kit may exhibit these
symptoms.
1. Adjust the "start" trimmer on the
voltage PC board. It should be
slightly higher than the weld
voltage.
See
Starting Charac-
teristics
in the
Operation
section
of this manual.
3. Put the Lincoln power source in
the "Machine Control" mode.
Jumper the "BYPASS" pins on
the LN-9 GMA voltage PC
board. Adjust the weld voltage
from the power source for the
process being used. If the correct voltage cannot be set, the
power source may be faulty.
4.
Check for correct control cable
connections to the power supply .
1. The voltage PC board may be
faulty. Replace.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.
Page 88
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TROUBLESHOOTING & REPAIR
F-24 F-24
LN-9 GMA Wire Feeder
T1 TRANSFORMER TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty . For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353
(WELD).
DESCRIPTION
This test will aid the technician in determining if the T1 transformer is functioning.
MATERIALS NEEDED
115VAC power supply
Phillips head screwdriver
Volt/ohmmeter (multimeter)
This procedure takes approximately 20 minutes to perform.
Page 89
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TROUBLESHOOTING & REPAIR
F-25 F-25
LN-9 GMA Wire Feeder
T1 TRANSFORMER TEST (continued)
TEST PROCEDURE
1. Remove input power to the LN-9 GMA wire
feeder.
2. Using the phillips head screwdriver, remove
the screws holding the left side cover
assembly.
3. Disconnect lead #532 from the power PC
board terminal. See Figure F.1.
Electric Shock can kill.
• With power applied,
there are high voltages
inside the wire feeder.
Do not reach into the
wire feeder or touch any
internal part of the wire
feeder while power is
applied.
4. Apply power (115VAC) to the T1 transformer
primary leads #31 and #532. See Figure F.1
and the Wiring Diagram.
5. Using the volt-ohmmeter, check for 28VAC
at secondary leads #526 and #527. See
Figure F.1. Place the meter probes where
the leads attach to the power PC board terminals.
WARNING
FIGURE F.1 – LEAD #532 AT POWER PC BOARD
115 VAC
T1
TRANSFORMER
LEAD 526
LEAD 532
LEAD 31
LEAD 527
Page 90
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TROUBLESHOOTING & REPAIR
F-26 F-26
LN-9 GMA Wire Feeder
6. Using the volt/ohmmeter , check for 10VAC at
secondary leads #601 and #602. Typically,
these leads are yellow. Place the probes at
the lead splices. See Figure F.2.
7. With 115VAC applied to the primary leads
#532 and #31, if either or both of the secondary voltages are missing or low the T1
transformer may be faulty. Replace the
transformer.
8. After the test is completed, disconnect the
115VAC from the T1 transformer primary
leads. Reconnect lead #532 to the power
PC board terminal. Close the left side cover
assembly and re-assemble the screws.
T1 TRANSFORMER TEST (continued)
FIGURE F.2 – SECONDARY LEADS #601 AND #602 AT LEAD SPLICES
LEAD 601
LEAD 602
Page 91
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TROUBLESHOOTING & REPAIR
F-27 F-27
LN-9 GMA Wire Feeder
WARNING
T2 TRANSFORMER TEST
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).
DESCRIPTION
This test will aid the technician in determining if the T2 transformer is functioning.
MATERIALS NEEDED
115VAC power supply
Phillips head screwdriver
Volt/ohmmeter (multimeter)
This procedure takes approximately 20 minutes to perform.
Page 92
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TROUBLESHOOTING & REPAIR
F-28 F-28
LN-9 GMA Wire Feeder
T2 TRANSFORMER TEST (continued)
FIGURE F.3 – “PROTECTION CIRCUIT TROUBLESHOOTING” NAMEPLATE
PROTECTION CIRCUIT
TROUBLESHOOTING NAMEPLATE
TEST PROCEDURE
1. Remove input power to the LN-9 GMA wire
feeder.
2. Using the phillips head screwdriver, remove
the screws holding the left side cover
assembly.
3. Lift the right side cover assembly.
4. Using the phillips head screwdriver, remove
the two screws from the Protection Circuit
Troubleshooting nameplate. Remove the
nameplate as far as the lead length will
allow. See Figure F.3.
Page 93
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TROUBLESHOOTING & REPAIR
F-29 F-29
LN-9 GMA Wire Feeder
T2 TRANSFORMER TEST (continued)
4. Locate the T2 transformer primary lead
#32A connected to the 5 amp circuit breaker. Remove lead #32Afrom the circuit breaker. See Figure F.4 and the Wiring Diagram.
5. Lift the left side cover assembly.
6. Locate T2 transformer primary lead #531
connected to the R1 2-ohm resistor. See the
Wiring Diagram. See Figure F.4.
FIGURE F.4 – T2 PRIMARY LEADS #32A AT 5 AMP CIRCUIT BREAKER AND #531 AT R1 RESISTOR
LEAD 32A
LEAD 531
R1 RESISTOR
CIRCUIT
BREAKER
Page 94
TROUBLESHOOTING & REPAIR
F-30 F-30
LN-9 GMA Wire Feeder
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T2 TRANSFORMER TEST (continued)
Electric Shock can kill.
• With power applied,
there are high voltages
inside the wire feeder.
Do not reach into the
wire feeder or touch any
internal part of the wire
feeder while power is
applied.
7. Insulate the T2 transformer primary leads
#531 and #32A and apply 115 VAC power.
See the Wiring Diagram and
Figure F.4.
8. Using the volt/ohmmeter, check for approximately 24VAC at the T2 transformer secondary leads #621 and #620. Place the
probes where the leads connect on the trigger PC board. See Figure F.5.
9. With 115VAC applied to the primary leads
#531 and #32A, if the secondary voltage is
missing or low the T2 transformer may be
faulty. Replace the T2 transformer.
10. After the test is completed, disconnect the
115VAC from the T2 transformer primary
leads #531 and #32A. Reconnect lead #32
to the circuit breaker. Re-attach the
Protection Circuit Troubleshooting nameplate. Close the right and left side cover
assemblies and replace all previously
removed screws.
FIGURE F.5 – T2 SECONDARY LEADS #621 AND #620 ON TRIGGER PC BOARD
LEAD
621
TRIGGER
PC BOARD
LEAD
620
WARNING
Page 95
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TROUBLESHOOTING & REPAIR
F-31 F-31
LN-9 GMA Wire Feeder
WARNING
WIRE DRIVE MOTOR TEST
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).
DESCRIPTION
This test will help determine if the drive motor is functioning properly.
MATERIALS NEEDED
Phillips head screwdriver
Analog volt/ohmmeter (multimeter)
This procedure takes approximately 12 minutes to perform.
Page 96
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TROUBLESHOOTING & REPAIR
F-32 F-32
LN-9 GMA Wire Feeder
WIRE DRIVE MOTOR TEST (continued)
FIGURE F.6 – LEAD #539 AND #541 AT POWER PC BOARD TERMINAL STRIP
LEAD 539
LEAD 541
TEST PROCEDURE
1. Remove input power to the LN-9 GMA wire
feeder.
2. Remove any electrode wire or disengage
the drive rolls.
3. Using the phillips head screwdriver, remove
the screws from the left side cover assembly.
4. Lift the left side cover assembly.
5. Locate leads #539 and #541 at the power
PC board terminal strip. See Figure F.6.
Page 97
ELECTRIC SHOCK can kill.
• With power applied,
there are high voltages
inside the wire feeder.
Do not reach into the
wire feeder or touch any
internal part of the wire
feeder while power is
applied.
6. Apply 115 VAC power.
7. With the gun trigger activated or the gun terminals jumpered together (see the Wiring
Diagram), check the motor armature volts at
leads #541(+) and #539(-). Normal is 5 to
95VDC depending on the wire feed speed
setting. As the armature voltage is increased
the wire feed speed should increase.
8. If the above voltages are present and the
motor does not operate, the motor, motor
brushes or gear box may be faulty.
If the armature voltage is missing or not correct, the power board or 1CR relay may be
faulty.
If the motor is running at high speed and the
armature voltage is high and uncontrollable,
proceed with the
Hall Effect Module Test.
TROUBLESHOOTING & REPAIR
F-33 F-33
LN-9 GMA Wire Feeder
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WIRE DRIVE MOTOR TEST (continued)
WARNING
Page 98
HALL EFFECT MODULE TEST AND ALIGNMENT
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).
DESCRIPTION
This test will help determine if the Hall Effect Module is correctly aligned and functioning properly .
MATERIALS NEEDED
9/16” Wrench
Analog volt/ohmmeter (multimeter)
Phillips head screwdriver
TROUBLESHOOTING & REPAIR
F-34 F-34
LN-9 GMA Wire Feeder
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WARNING
The Hall Effect Module Test takes approximately
10 minutes to perform.
The Hall Effect Alignment Procedure takes approximately
10 minutes to perform.
Page 99
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TROUBLESHOOTING & REPAIR
F-35 F-35
LN-9 GMA Wire Feeder
HALL EFFECT MODULE FEEDBACK
TEST PROCEDURE
1. Remove the input power to the LN-9 GMA
wire feeder.
2. Remove any electrode wire or disengage
the drive rolls.
3.
Using the phillips head screwdriver, remove
the screws from the left side cover assembly.
4. Lift the left side cover.
5. Locate the hall effect leads #510, #525 and
#555 on the control PC board. See Figure
F.7.
HALL EFFECT MODULE TEST AND ALIGNMENT (continued)
FIGURE F.7 – LEADS #525, #510, #555 ON CONTROL PC BOARD
LEAD
525
LEAD
510
LEAD
555
Page 100
ELECTRIC SHOCK can kill.
• With power applied,
there are high voltages
inside the wire feeder.
Do not reach into the
wire feeder or touch any
internal part of the wire
feeder while power is
applied.
6. Apply input power to the LN-9 GMAand test
for 15VDC at leads #525(+) to #510(-). This
is the supply voltage from the control PC
board to the hall effect module. If the correct
voltage is present, proceed to the next step.
If the voltage is missing, check the wiring
and perform the
General Power Supply
Test.
7. With the gun trigger activated or the gun terminals jumpered together (see the Wiring
Diagram), check leads #555(+) to #510(-) for
the presence of between 4.5 - 10.5VDC.
(The motor must be running.) This is the
feedback voltage from the hall effect module
to the control PC board. This voltage is
dependent upon motor speed. If the feedback voltage is missing or does not vary with
motor speed, the hall effect module may be
faulty.
TROUBLESHOOTING & REPAIR
F-36 F-36
LN-9 GMA Wire Feeder
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WARNING
HALL EFFECT MODULE TEST AND ALIGNMENT (continued)
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